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Lincoln Electric IM10040 User's Manual

1. In All operator controls and adjustments are located on the case front of the Power Wave See Figure B 1 1 LEFT DISPLAY Shows wire feed speed or amper age 2 LEFT Adjusts value in left display 3 MAIN DISPLAY Shows detailed welding and diag nostic information 4 LEFT BUTTON Changes the Main display to show the Weld Mode or Arc Control 5 MAIN KNOB Changes the values on the Main dis play 6 PROCEDURE BUTTON Selects A or B proce dure or gun control 7 2 STEP 4 STEP BUTTON Toggles between 2 step and 4 step trigger operation 8 MEMORIES BUTTONS For selection of common procedures 9 ON OFF SWITCH Controls power to the Power Wave C300 10 RIGHT DISPLAY Shows voltage or trim 11 THERMAL LIGHT Indicates when machine has thermal fault 12 RIGHT KNOB Adjusts value in right display 13 SET UP Lights when machine is in set up mode 14 RIGHT BUTTON Used to toggle start options and to end options POWER WAVE C300 LINCOLN Bes OPERATION De CASE BACK CONTROLS FIGURE B 2
2. 1 1 1 5secm 1 1 Statin TTL TM T 4AX I Be R L Gi TER G cic eni nel ke ke axa ei 1 1 Weld Ie 1 1 1 Crater i Run in i Off 1 1 1 1 1 1 1 1 4 POWER WAVE C300 LINCOLN B 24 8 25 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 Burnback reduces the occurrence of wire to sticking into the weld pool at the end of a weld and conditions the end of the wire for the next arc start See Figure B 15 In 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 start output and wire is advanced towards the work piece at the run in WFS If an arc is not estab lished within 1 5 s
3. 72 3 64 Pulse 4043 Ar UltimArc Control EFFECT RANGE DESCRIPTION PULSE For Pulse modes Arc Control FREQUENCY changes the pulsing frequency Low 10 0 to When the frequency changes High 10 0 the Power Wave system auto matically adjusts the back ground current to maintain a similar heat input into the weld Low frequencies give more con trol over the puddle and high frequencies minimize spatter For Pulse On Pulse modes FREQ MODULATION Arc controls changes the frequ PULSE ON PULSE ency modulation The freque ncy modulation controls the spacing of the ripples in the weld Use low values for slow travel speeds and wide welds and high values for fast travel Speeds and narrower welds Low 10 0 to High 10 0 START OPTIONS EFFECT DESCRIPTION Adjusts the time that shielding gas flows after the trigger is pulled and prior to feeding wire Postflow Time RUN IN WFS Run in sets the wire feed speed from the time the trigger is pulled until an arc is estab lished The Start Procedure controls the WFS Trim at a specified time at the beginning of the weld During the start time the machine will ramp up or down from the Start Procedure to the preset Welding Procedure END OPTIONS EFFECT FUNCTION Adjust the time welding will continue even if the trigger Crater Procedure is still pulled This option has no effect in
4. de A 7 Loading Spool Wire icc xn n onl e h ye n bi Vedan k v eee hoe ee A 8 Wire Drive Configuration rebar e ree d A 9 Procedure to Install Drive Rolls and Wire Guides A 9 GUN USOC PEE 10 Feeding Electrode and Brake Adjustment 10 Drive Roll Pressure 10 TG WIGING ate 11 SMAW Welding DK itu ie eue e Xe A 11 Ope ati OM Section 8 sri nc B 1 Graphic Symbols tortor coiere ka rm cete oven B 1 PowerUp SEQUENCE eerte treten terri een de ie B 1 rrr B 1 Product rte autetn deii dee dade ee eser b v B 2 Recommended Processes and Equipment B 2 Equipment ere E de 8 3 Common Equipment Packages 8 3 Design rm _ r mp 8 3 Case Front is beeen pation dante 8 4 Case Back 0346 411061 Em 8 5 Internal Controls 6 Making a Weld with Waveform Technology Power B 7 thru B 16 Procedure Memory Panel Op
5. CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electric
6. 1 ETHERNET CONNECTOR 2 POWER CORD 3 GAS CONNECTION GMAW AND FCAW 4 Gas Connection GTAW POWER WAVE C300 LINCOLN 656 OPERATION B 6 INTERNAL CONTROLS Code 11479 FIGURE B 3 1 SPINDLE BRAKE 2 WIRE DRIVE PRESSURE ARM 3 THUMB SCREW FOR SECURING THE WELDING GUN 4 GUN BUSHING 5 SOCKET HEAD CAP SCREW FOR SECURING THE GUN BUSHING 6 GAS CONNECTION GMAW OR FCAW GUN 7 12 PINCONNECTOR 8 NEGATIVE STUD 9 POSITIVE STUD 10 4 PIN TRIGGER RECEPTACLE 11 COLD INCH GAS PURGE SWITCH 12 GAS CONNECTION GTAW POWER WAVE C300 LINCOLN ou OPERATION aad MAKING A WELD WITH WAVEFORM TECHNOLOGY POWER SOURCES A WARNING MAKING A WELD 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 not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements The available range of a welding program may not be suitable for all applications and the build user is and must be solely responsible for welding program selec tion Choose the electrode material electrode size shield ing gas and process GMAW GMAW P etc appro priate for the material to be welded Select the weld mode that
7. Do not touch electrically hot parts Always connect the POWER WAVE C300 grounding lug located inside the reconnect input access door to a proper safety Earth ground SELECT SUITABLE LOCATION The POWER WAVE C300 will operate in harsh environ ments Even so it is important that simple preventative measures are followed in order to assure long life and reli able operation e The machine must be located where there is free circula tion of 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 to a minimum The use of air filters on the air intake is not recommended because normal air flow may be restricted Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles Do not mount the POWER WAVE C300 over com bustible surfaces Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 060 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides INSTALLATION A 3 LIFTING 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 attemp
8. 8 33 OPERATION B 33 USER DEFINED PARAMETERS Arc Start Loss Error Time This option can be used to optionally shut off output if an arc is not established or is lost for a specified amount of time Error 269 will be displayed if the machine times out If the value is set to OFF machine output will not be turned off if an arc is not established nor will output be turned off if an arc is lost The trigger can be used to hot feed the wire default If a value is set the machine output will shut off if an arc is not established within the specified amount of time after the trigger is pulled or if the trigger remains pulled after an arc is lost This is disabled while welding in Stick TIG or Gouge To prevent nuisance errors set Arc Start Loss Error Time to an appropriate value after considering all welding parameters run in wire feed speed weld wire feed speed electrical stick out etc To prevent subsequent changes to Arc Start Loss Error Time the setup menu should be locked out by setting Preference Lock Yes using the Power Wave Manager software Sense From Studs Use this option for diagnostic purposes only When power is cycled this option is automatically reset to False False Voltage sensing is automatically determined by the selected weld mode and other machine settings default True Voltage sensing is forced to studs Sense Leads Selection Used in place of DIP switches for configuration of the work and electrode sen
9. Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility WARNING 0 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 C300 LINCOLN amp zig TROUBLESHOOTING E 2 USING THE STATU
10. Connect the shielding gas hose to the new gun bushing if required 9 Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned 10 Tighten the socket head cap screw 11 Insert the welding gun into the gun bushing and tighten the thumb screw PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES WARNING Turn the input power OFF at the welding power source before instal lation 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 not operate with covers panels or guards removed or open Only qualified personnel should perform mainte nance work Turn power off at the welding power source Release the idle roll pressure arm Remove the outer wire guide by turning the knurled thumbscrews counter clockwise to unscrew them from the feed plate 4 Rotate the triangular lock and remove the drive rolls LOCKED POSITION UNLOCKED POSITION 5 Remove the inner wire guide 6 Insert the new inner wire guide groove side out over the two locating pins in the feed plate 7 Install a drive roll on each hub assembly secure with the tri
11. EQUIPMENT LIMITATIONS Maximum gun length is 25 ft 7 6m for push only systems Maximum gun length is 50 ft 15 2 for push pull systems Maximum spool size is 12 in 305 mm diameter Maximum spool weight is 44 Ib 20 kg Other gun bushings are required for welding guns that do not have a Magnum Tweco 2 4 compati ble back end POWER WAVE C300 LINCOLN 5 3 OPERATION 5 3 DESIGN FEATURES Patent pending dual spring pressure arms have Loaded with Standard Features sensitivity for feeding soft wires without crushing them and have plenty of compression force for Multiple process DC output range 300 Amps feeding solid or stiff wires 200 600 VAC 1 3 phase 50 60 2 input power All gear driven rolls for more feeding force New and Improved Line Voltage Compensation Changeable gun bushings easily accept guns from holds the output constant over wide input voltage other manufacturers fluctuations Brass to brass connections between the electrode Utilizes next generation microprocessor control connection and the gun minimize voltage drop vari based on the ArcLink platform ations resulting in consistent arc performance all State of the art power electronics technology yields day every day TM superior welding capability Powerful quiet motor with integrated tachometer for Electronic over current protection accurate WFS regulation Input over voltage protecti
12. POWER WAVE C300 LINCOLN 8 24 Shielding Gas Power Source Output WFS OPERATION EXAMPLE 4 4 STEP TRIGGER Trigger Interlock The 4 step trigger can be configured as a trigger inter lock Trigger interlock adds to the welder s 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 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 5 seconds the wire feed speed will jump to the welding wire feed speed WELD The power source output and the wire feed speed continue at the weld settings Welding continues when the trigger is pulled a second time POSTFLOW As soon as the trigger is released for the second time the power source output and the wire feed speed are turned OFF Shielding gas flows until the post flow timer expires FIGURE B 14 4 Step Trigger Start OFF Crater OFF Burnback OFF Trigger Pulled Arc Established Trigger Released Trigger Pulled Trigger Released wW 5 Idle Preflow Strike Weld Postflow i Idle On o Weld
13. 1 ae 356 246 358 1 POWER WAVE C300 LINCOLN E 2 DIMENSION PRINT or 27 43 5 e T y U by 72 4 POWER WA VI D NCOLN j j ELECTRIC a Op Y E El lt 13 94 lt 24 04 POWER WAVE C300 LINCOLN NOTES POWER WAVE C300 LINCOLN 5 NOTES POWER WAVE C300 LINCOLN 5 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO BIR Chinese Korean Do not touch electrically live
14. 4 Step operation The 2 Step 4 Step trigger has no effect when weld ing with SMAW 403 0 2 Step Trigger 2 Step trigger operation is the most common When the gun trigger is pulled the welding system power source and wire feeder cycles through the arc start ing sequence and into the main welding parameters The welding system will continue to weld as long as the gun trigger is activated Once the trigger is released the welding system cycles through the arc ending steps 4 Step Trigger 4 Step trigger operation gives the welder additional control in the welding sequence 4 Step trigger allows the welder to choose the arc start weld and arc end time It may also be set up to work as a trigger inter lock POWER WAVE C300 LINCOLN 8 21 Shielding Gas 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 5 seconds the wire feed speed will jump to the welding wire feed speed WELD The power source output and the wire feed speed continue at the weld settings for
15. Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information mus
16. PANTHER PUSH PULL GUN Air Cooled 2577 ft 7 6m Requires 2910 1 7 to 12 pin adapter K2874 3 PANTHER PUSH PULL GUN Air Cooled 50 ft 15 2m Requires K2910 1 7 pin to 12 pin adapter K2875 2 PANTHER PUSH PULL GUN Water Cooled 25 ft 7 6 m Requires K2910 1 7 pin to 12 pin adapter POWER WAVE C300 LINCOLN MAINTENANCE SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill 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 C300 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 cal ibration of output Voltage and Current should be checked yearly CALIBRATION SPECIFICATION Output Voltage and Current are calibrated at the fac tory Generally the mac
17. fast travel speed OPERATION B 14 ALUMINUM GMAW P AND GMAW PP ALUMINUM PULSE WELDING Synergic GMAW P Pulsed MIG welding is ideal for low spatter out of position and reduced heat input applications During pulse welding the welding cur rent continuously switches from a low level to a high level and then back again Each pulse sends a small droplet of molten metal from the wire to the weld pud dle Pulse welding controls the arc length with Trim instead of voltage When trim arc length is adjusted the Power Wave automatically recalculates the volt age current and time of each part of the pulse wave form for the best result Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 for a 3 4 19mm electrode stick out Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length See Figure B 10 FIGURE B 10 Trim 1 50 Arc Length Long Trim 1 00 Arc Length Medium Trim 50 Arc Length Short POWER WAVE C300 LINCOLN B 15 OPERATION Bala ALUMINUM GMAW P PULSED MIG AND GMAW PP PULSE ON PULSE WELDING BASIC OPERATION 01 220 1 1 06 152 Less More Shorter Longer Deposition Deposition Are Arc CONTROL OPTIONS WELD MODES WIRE SIZE ELECTRODE AND GAS 0 035 3 64 1 16 ALUMINUM 4043 Ar 149 72 74 ALUMINUM 4043 98 99 100 ALUMINUM 5356 Ar 152 76 78 ALUMINUM 5356 101 102 103
18. occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any 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 Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier
19. push only guns 12 pin connector for Push pull guns foot pedal remote controls Hand amptrols Z F gt CT Q T TI 0 O gt CABLE INDUCTANCE AND ITS _ EFFECTS ON WELDING Whenever possible always weld in a direction away from the work ground connection Excessive cable inductance will cause the welding performance to degrade There are several factors that contribute to the overall inductance of the cabling system including cable size and loop area The loop area is defined by the separation distance between the electrode and work cables and the overall welding loop length The welding loop length is defined as the total of length of the electrode cable A work cable B work path C see Figure A 3 Function 4 Wiring Supply Voltage for Dual Procedure Dual Procedure Input Trigger Input Supply Voltage for Trigger CANL CANH Remote Pot Common Remote Pot Wiper Remote Pot 10VDC ArcLink Peripheral Sense Trigger Trigger Power Common Power Motor Negative Motor Positive 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 minimize the loop area Since the most significant fac tor in cable inductance is the welding loop length avoid excessive lengths and do not coil excess cable For long work piece lengths a sliding ground should be considered to keep the total welding loop lengt
20. ry 3 may not have any WFS limits Parameters are always constrained by machine limits When memory limits are enabled the parameter will flash whenever an attempt is made to exceed the memory limit value The parameter will not flash if an attempt is made to exceed the machine limit The system machine limits are Parameter Range Units feeder dependent UltimArc Control Limits may be set for Wire Feed Speed Amperage Voltage Trim UltimArc Control Start Time Run In WFS Crater Time Burnback Time Postflow Time Weld modes cannot be selected through the Limits Setup menu and must be chosen and saved to mem ory before entering the Limits Setup Menu Set Limits Press 5 seconds 1 8 vec JPL set limits press the desired memory button 1 8 and hold for 5 seconds Release the memory button when the LED begins to blink rapidly and the MSP4 displays Memory X Set Limits as shown below setup Memory 2 Set Limits WELD MODE UltimArc Control START OPTIONS END 5 POWER WAVE C300 LINCOLN 8 19 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 C se
21. selected the elec trode and drive mechanism are always HOT to work and ground and could remain HOT sev eral seconds after the gun trigger is released Do not operate with covers panels or guards removed or open Only qualified personnel should perform mainte nance work The POWER WAVE C300 s optimum drive roll pres sure varies with type of wire surface condition lubri cation and hardness Too much pressure could cause birdnesting but too little pressure could cause wire feed slippage with load and or acceleration The opti mum drive roll setting can be determined as follows INSTALLATION A 10 1 Press end of gun against a solid object that is elec trically isolated from the welder output and press the gun trigger for several seconds 2 f the wire birdnests jams or breaks at the drive roll the drive roll pressure is too great Back the pressure setting out turn run new wire through gun and repeat above steps 3 If the only result is drive roll slippage disengage the gun pull the gun cable forward about 6 150 mm There should be a slight waviness in the exposed wire If there is no waviness the pressure is too low Increase the pressure setting turn reconnect the gun tighten locking clamp and repeat the above steps PRESSURE ARM ADJUSTMENT The pressure arm controls the amount of force the drive rolls exert on the wire Proper adjustment of pressure arm gives the best welding per
22. 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 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 C300 LINCOLN amp ES TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Basic Machine Problems Input fuses keep blowing 1 Improperly sized input fuses 1 Make sure fuses are properly sized See installation section of this manual for recommended sizes 2 Improper Weld Procedure requir 2 Reduce output current duty ing output levels in excess of cycle or both machine rating Major physical or electrical dam Contact your local authorized age is evide
23. the preset Welding Procedure Start Procedure 5 STD CV MIG setup WELD MODE UltimArc Contro UltimArc Control PINCH Pinch controls the arc characte ristics when short arc welding Soft 10 0 to Crisp 10 0 START OPTIONS END OPTIONS END OPTIONS DESCRIPTION Spot Timer Adjust the time welding will continue even if the trigger Crater Procedure is still pulled This option has no effect in 4 Step Trigger Mode Crater Procedure controls the WFS and Volts for a specified time at the end of the weld after the trigger is released During the Crater time the machine will ramp up or down from the Weld Procedure to the Crater Procedure The burnback time is the amount of time that the weld output continues after the wire stops feeding It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start Burnback Adjusts the time that shielding gas flows after the welding out put turns off Postflow Time POWER WAVE C300 LINCOLN 8 11 GMAW MIG SYNERGIC WELDING For each wire feed speed a corresponding voltage is preprogrammed into the machine The nominal pre programmed voltage is the best average voltage for a given wire feed speed but may be adjusted to prefer ence When the wire feed speed changes the Power Wave automatically adjusts the volta
24. the selected procedure memory USER MEMORIES ARE COPIED TO PROCEDURE User memories work by copying the weld procedure from one of the eight memories into either the A or B procedure Weld procedures are saved into the memories only when the operator chooses 8 USER MEMORIES PROCEDURE MEMORY Using Procedure Memories Procedure memories can be selected by choosing either A or B procedure directly with the memory panel or by selecting GUN and using a dual proce dure gun to select between procedure A and B When selecting procedures with the gun switch A or B will flash to show which procedure is active PRESS TO SELECT PROCEDURE OPERATION USER MEMORIES Recall a memory with memory buttons To recall a user memory press one of the eight user memory buttons The memory is recalled when the button is released Do not hold the button for more than two seconds when recalling a user memory Recall a memory with the gun trigger If desired memories 1 through 8 can be recalled with the gun trigger For example to recall memory 3 quickly pull and release the gun trigger 3 times without welding To recall memory 1 quickly pull and release the gun trigger 9 times without welding Note the wire feeder is factory set with this feature
25. to exit and leave limits unchanged Enabling Disabling Limits Enable Disable Limits Press 10 seconds 69 LS LES LER TER Limits for each memory may be enabled or disabled by pressing and hold the appropriate memory button for 10 seconds Release the memory button when the MSP4 display shows the following serup MEMORY 2 LIMITS ENABLE DISABLE WELD MODE START OPTIONS ItimArc Control 9 END OPTIONS If the passcode does not equal zero enter the passcode now Ifthe passcode is zero 0000 SETUP will light and the MSP4 displays the following C setup ENABLE LIMITS Yes No WELD MODE START OPTIONS UltimArc Control END OPTIONS Press the left MSP4 button YES to enable limits or the right MSP4 button NO to disable limits Disabling limits does not change any limits values that may have been previously set POWER WAVE C300 LINCOLN OPERATION B 20 2 STEP 4 STEP TRIGGER OPERATION 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 trig ger 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
26. 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 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 C300 LINCOLN 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 OOOO O 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 chopper has errors If cycling the input power on the machine does not clear the error contact the Se
27. 030 0 035 0 045 0 052 Steel 10 20 24 Steel Ar Mix 94 21 61 31 41 lished The Start Procedure controls the WFS Volts at a specified Start Procedure Stainless Ar He CO Aluminum 4043 Ar Aluminum 5356 Ar 63 33 43 time at the beginning of the weld During the start time the machine will ramp up or down STEEL WELDMODE UltimArc Control UltimArc Control EFFECT RANGE DESCRIPTION PINCH EFFECT Pinch controls the arc characte ristics when short arc welding 10 0 to 10 0 from the Start Procedure to the preset Welding Procedure START OPTIONS END OPTIONS END OPTIONS EFFECT DESCRIPTION Spot Timer Adjust the time welding will continue even if the trigger is still pulled This option has no effect in 4 Step Trigger Mode Crater Procedure controls the WFS and Volts for a specified time at the end of the weld after the trigger is released During the Crater time the machine will ramp up or down from the Weld Procedure to the Crater Procedure Burnback The burnback time is the amount of time that the weld output continues after the wire stops feeding It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start Postflow Time Adjusts the time that shielding gas flows after the welding out put turns off Crater Procedure POW
28. 4 Step Trigger Mode Crater Procedure controls the WFS and Volts for a specified time at the end of the weld after the trigger is released During the Crater time the machine will ramp up or down from the Weld Procedure to the Crater Procedure The burnback time is the amount of time that the weld output continues after the wire stops feeding It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start Postflow Time Adjusts the time that shielding gas flows after the welding out put turns off Burnback POWER WAVE C300 LINCOLN 5 16 GTAW TIG WELDING The Power Wave C300 is excellent for Touch Start TIG welding OPERATION B 16 BASIC OPERATION Maximum Amperage wrs amps 9 OFF E OUTPU OUTPUT ON OFF CONTROL OPTIONS WELD MODE 1005 TOUCH START 3 START OPTIONS No Arc starting Options are active for Touch Start TIG setup TOUCH START TIG WELD MODE UltimAre Control UltimArc Control No UltimArc Control are active for Touch Start WELD MODE SEARCHING The Weld Mode Search feature allows the selection of a welding mode based on certain criteria wire size process type etc SEARCHING FOR A WELD MODE To search for a mode turn the control knob until Weld Mode Search is displayed This will appea
29. AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH limits 5 c Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod uct
30. ER WAVE C300 LINCOLN 8 12 OPERATION B 12 STEEL AND STAINLESS SYNERGIC GMAW P PULSED MIG WELDING When pulse welding the power source primarily regu lates the arc current not the arc voltage During a pulsing cycle arc current is regulated from a low background level to a high peak level and then back down to the low background level The average arc voltage increases and decreases as the average arc current is increased or decreased The peak current back ground current rise time fall time and pulse fre quency all affect the average voltage Since the aver age voltage for a given wire feed speed can only be determined when all the pulsing waveform parameters are known a unit less value called is used for adjusting the arc length Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 Increasing the trim value increases the arc length Decreasing the trim value decreases the arc length Pulse welding modes are synergic using wire feed speed as the main control parameter As the wire feed speed is adjusted the power source adjusts the waveform parameters to maintain good welding char acteristics Trim is used as a secondary control to change the arc length for material conditions or indi vidual preference See Figure B 5 FIGURE B 5 IIl Trim 1 00 Arc Length Medium Trim 50 Arc Length Short ULTIMARC CONTROL See Figure B 6 UltimArc Control ad
31. ER WAVE C300 is powered it can take as long as 30 seconds for the machine to be ready to weld During this time period the user inter face will not be active DUTY CYCLE The POWER WAVE C300 is rated at 250 amps at 26 5 volts with a 100 duty cycle It is further rated to provide 275 amps at 27 8 volts with a 60 duty cycle and 300 amps at 29 volts with a 40 duty cycle The duty cycle is based on a ten minute period A 60 duty cycle represents 4 minutes of welding and 6 min utes of idling in a ten minute period POWER WAVE C300 LINCOLN 5 OPERATION PRODUCT DESCRIPTION The Power Wave C300 is a high performance multi process machine with GMAW FCAW SMAW DC TIG and pulse capability It will offer a premier weld ing 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 Single and Three Phase Power lt 95 Power factor optimizes available electrical capacity especially useful when limited to inputs of 230VAC 1 phase Environmentally Hardened IP23 rated for operating in difficult environments Versatile Feeding Options Standard Mig guns Spool guns and Push pull guns Ethernet connectivity allows access to the Power Wave utilities software tools
32. ERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING The Above For Gasoline Engines Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS 1 h To avoid scalding do not remove the FOR ENGINE us de hen the engine powered equipment E Wi 7 hot or pressure cap when the engine IS 1 8 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS 54 1 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 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 v
33. NECTION 4 PIN GUN TRIGGER CONNECTOR TO GAS SUPPLY a GAS HOSE we Po REMOTE CONTROL RECEPTACLE FOOT AMPTROL OPTIONAL POWER WAVE C300 LINCOLN E OPERATION E SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE A WARNING ELECTRIC SHOCK CAN KILL Unless using COLD FEED fea ture when feeding with gun trig ger the electrode and drive mechanism are always electri cally energized and could remain energized several sec onds after the welding ceases Do not touch electrically live part or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves not operate with covers panels or guards removed or open FUMES AND GASSES be 3 dangerous Keep your head out of fumes B e Use ventilation or exhaust to remove fumes from breathing NE WELDING SPARKS can cause gt fire or explosion zone Keep flammable material away AZ SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN UAL ARC RAYS can burn Wear eye ear and body protec tion GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL WARNING OR CAUTION DANGEROUS VOLTAGE POSITIVE OUTPUT NEGATIVE OUTPUT HIGH TEMPERATURE STATUS PROTECTIVE GROUND A 1 4 POWER UP SEQUENCE When the POW
34. OR ARC WELDING A 15 ft work cable is provided with the POWER WAVE C300 This cable is appropriately sized for all of the POWER WAVE C300 s 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 Always use the largest work cables that is practical and be sure all connections are clean and tight Note Excessive heat in the weld circuit indicates undersized cables and or bad connections REMOTE SENSE LEAD SPECIFICA TIONS Since the POWER WAVE C300 has the ability to be in close proximity to the welding arc the POWER WAVE C300 does not require the use of remote sense leads SEMI AUTOMATIC WELDING POLARITY Most GMAW welding procedures use Electrode Positive welding For these applications connect the wire drive s connection block to the positive output stud and connect the work lead to the negative out put stud Some FCAW SS does use Electrode Negative Polarity For these applications connect the wire drive s connection block to the negative output stud and connect the work lead to the positive output stud POWER WAVE C300 LINCOLN 5 6 CABLE CONNECTIONS There are two circulars connector in the wire drive compart ment See 4 pin and 12 pin Figure A 2 Table A 1 INSTALLATION TABLE A 1 4 pin trigger con nector for
35. POWER WAVE C300 mE For use with machines having Code Numbers 11672 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 And most importantly think before you act and be careful C US OPERATOR S MANUAL 180 9001 p mm Inc 4 Manufactured Under a ogra d by LINCOLN 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 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm 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 Diesel Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEAR
36. RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Wave C300 is a high speed multi process power source capable of regulating the current voltage or power of the welding arc With an output range of 5 to 300 amperes it supports a number of standard processes including synergic GMAW GMAW P FCAW FCAW SS SMAW GTAW and GTAW P on various materials especial ly steel aluminum and stainless steel The following capabilities are supported Push pull 12 pin connection Panther and Cougar Remote foot pedal K870 2 or hand amptrol K963 4 are a 12 pin connection Standard MIG gun trigger connection 4 pin The unit will have the K1500 1 gun bushing for LECO backend connections Gas Stud adapter K2505 2 allow for easy TIG connec tions Simple process to switch between different welding processes PROCESS LIMITATIONS The software based weld tables of the Power Wave amp C300 limit the process capability within the output range and the safe limits of the machine In general the processes will be limited to 025 045 solid steel wire 035 045 stainless wire 035 052 cored wire and 035 3 64 Aluminum wire 1 16 Aluminum wire is not supported The following items will not be supported on this product but may be supported by other product in the product portfo lio SIT AC welding processes A WARNING The Power Wave amp C300 is not recommended for pipe thawing
37. S LED TO There is an audible beeper associated with this input control TROUBLESHOOT SYSTEM PROBLEMS board s status light So the error codes on the input board can be detected through either the status light or the status 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 sys tem check the power source status light for error sequences as noted below Included in this section is information about the Status Lights and some basic troubleshooting charts for both machine and weld performance The status lights on the main control board and the wire drive module are dual color LED s Normal operation for each is steady green Where as the status light on the input There are two externally mounted status lights located Control board is one color Normal operation is for the status above the wire drive in the wire feeder compartment One of light to be off and the buzzer to be off the status lights is for the main control board labeled sta tus and one for the wire drive module The third status light is internal and is located on the input control board and can be seen by looking through the left case side louvers Error conditions are indicated in the fol
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39. Select Yes to access the diagnostic options in the menu Additional parameters will now appear in the setup menu P 101 P 102 etc POWER WAVE C300 LINCOLN 8 34 OPERATION B 34 USER DEFINED PARAMETERS View Fatal Logs Used for viewing all the system fatal logs Press the Right Button to enter the option Rotate Control Knob to select the desired fatal log to read Press the Right Button again to enter that log Rotating the Control Knob will scroll through the log displaying the log index number and fatal code Press the Left Button to back out to select another log Press the Left Button again to exit this option View Software Version Information Used for viewing the software versions for each board in the system Press the Right Button to enter the option Rotate Control 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 Control Knob to select another board or press the Left Button to exit this option View Hardware Version Information Used for viewing the hardware version for each board in the system Press the Right Button to enter the option Rotate Control Knob to select the desired board to read Press the Right Button again to read the hardware version Press the Left Button to back out to select another board Press the Left Button again to exit this option View Welding Software Information
40. TURES 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 Unsecured Parameters always adjustable P 101 through P 199 Diagnostic Parameters always read only P 501 through P 599 Secured Parameters only accessible through a p c or palm application SET UP FEATURES MENU See Figure B 16 1 To access the set up menu press the Right and Left buttons of the MSP4 panel simultaneously Note that the set up menu cannot be accessed if the system is welding or if there is a fault The sta tus LED is not solid green Change the value of the blinking parameter by rotat ing the SET knob 2 After changing a parameter it is necessary to press the Right hand button to save the new setting Pressing the Left button will cancel the change 3 To exit the set up menu at any time press the Right and Left buttons of the MSP4 panel simulta neously Alternately 1 minute of inactivity will also exit the set up menu FIGURE B 16 SETUP MENU Mode Select Panel MSP4 LED Indicator Left Right button button SET Knob POWER WAVE C300 LINCOLN 8 29 OPERATION B 29 USER DEFINED PARAMETERS This option is used to exit the setup menu When 0 is displayed press the Left Button to exit the setup
41. Used for viewing the Weld Set in the Power Source Press the Right Button to read the Weld Set version Press the Left Button to back out and exit this option View Ethernet IP Address Used for viewing the IP address of Ethernet compatible equipment Press the Right Button to read the IP Address Press the Left Button to back out and exit this option The IP address can not be changed using this option View Power Source Protocol Used for viewing the type of power source the feeder is connected to Press the Right Button to identify the power source as either LincNet or ArcLink Press the Left Button to back out and exit this option Encoder Lockout Locks one or both of the upper knobs encoders preventing the operator from changing wire feed speed amps volts or trim The function of each upper knob depends on the selected weld mode When a constant current weld mode is selected e g Stick TIG Gouge the upper right knob will always function as an on off switch This parameter can only be accessed using PowerWave Memory Change Lockout Determines if the memories can be overwritten with new contents No Memories can be saved and limits can be configured default Yes Memories cannot be changed saving is prohibited and limits cannot be re configured This parameter can only be accessed using Power Wave Manager software POWER WAVE C300 LINCOLN 55 35 OPERATION B 35 USER DEFINED PARAMETERS Memory Button Disabl
42. WIRE SIZES WIRE SIZES WIRE SIZES 50 700 ipm 025 045 030 3 64 035 045 035 052 1 3 17 8 m min 0 6 1 1mm 0 8 1 2mm 0 9 1 1mm 0 9 1 4mm WELDING PROCESS PROCESS OUTPUT RANGE AMPERES GMAW GMAW Pulse 40 70 VDC average 100 FCAW GTAW DC 5 300 24 VDC average 100V SMAW 5 280 60 VDC average 100V peak WIRE SPEED RANGE Wire Speed 50 700 IPM 1 27 17 8 m minute PHYSICAL DIMENSIONS K2675 2 18 8in 478mm 14 00in 356mm 27 4in 697mm 100 0lbs 47 6kg 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 155 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 C300 LINCOLN 5 3 SAFETY PRECAUTIONS Read this entire installation section before you start installa tion WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Turn off the input power to any other equipment connected to the welding system atthe disconnect switch or fuse box before work ing on the equipment
43. X ezido sel zia MEY cals 13 dik ye Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG 6 BIA Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR HS RM PBHOX A OHRBEE lt HA 3890 CL TRHORERMEL HDT FEU RA MOLDE XE IR ERRAND BA DIR FE ER SE EROR ST RR 7 BI 0 AIMS HA FYR 5 a lal il gl easly a al gly olg qall gal ag ls il LINCOLN 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
44. ZE 0 030 0 035 0 045 0 052 14 19 26 Tem 34 12 STEEL 035 Pulse Crisp ArMix 10 9 WELDMODE Control UltimArc Control EFFECT RANGE DESCRIPTION ARC FOCUS Arc Focus adjusts the arc from 10 0 SOFT to a wide soft arc good for out of 10 0 STIFF position work to a narrow stiff arc preferred for faster travel speeds The pulse frequency is lower with a soft arc and higher with a stiff arc Burnback Postflow Time POWER WAVEG LINCOLN Shorter CA vorrs TRIM Longer Arc START OPTIONS EFFECT DESCRIPTION Adjusts the time that shielding gas flows after the trigger is pulled and prior to feeding wire Postflow Time RUN IN WFS Run in sets the wire feed speed from the time the trigger is pulled until an arc is estab lished The Start Procedure controls the WFS Trim at a specified time at the beginning of the weld During the start time the machine will ramp up or down from the Start Procedure to the preset Welding Procedure Start Procedure START OPTIONS END OPTIONS END OPTIONS EFFECT FUNCTION Spot Timer Crater Procedure Adjust the time welding will continue even if the trigger is still pulled This option has no effect in 4 Step Trigger Mode Crater Procedure controls the WFS and Volts for a specified time at the end of the weld after the tri
45. al Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information E SAFETY i PRECAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment le
46. angular lock 8 Install the outer wire guide by aligning it with the pins and tightening the knurled thumbscrews SOCKET HEAD N 9 Close the idle arm and engage the idle roll pressure CAP SCREW arm Adjust the pressure appropriately LOOSEN TIGHTEN POWER WAVE C300 LINCOLN 5 10 GUN USED The Magnum 350PRO is the recommended gun for the POWER WAVE C300 Refer to the Magnum 350PRO s operators manual for installation instruc tions FEEDING ELECTRODE AND BRAKE ADJUSTMENT 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 If the electrode is not properly straightened it may not feed or may jam causing a birdnest 3 Insert the free end through the incoming guide tube 4 Press the Cold Inch key and push the electrode into the drive roll 5 Feed the electrode through the gun 6 Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped Do not over tighten DRIVE ROLL PRESSURE SETTING ELECTRIC SHOCK can kill Turn the input power OFF at the weld ing power source before installation or changing drive rolls and or guides Do not touch electrically live parts e When feeding with the gun trigger unless COLD FEED trigger mode is
47. aporiz ing on contact 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 fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrod
48. as long as the trigger is pulled POSTFLOW As soon as the trigger is released the power source output and the wire feed speed are turned OFF Shielding gas continues until the post flow timer expires FIGURE B 11 2 Step Trigger Start OFF Crater OFF 5 8 Burnback OFF o 5 E E 5 Preflow Run In Weld POWER WAVE C300 LINCOLN Pos flow Ide B 21 8 22 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 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 start output and wire is advanced towards the work piece at the Run In WFS If an arc is not estab lished within 1 5 seconds the power source output and wire feed speed skips to the weld settings OPERATION B 22 UPSLOPE Once the wire touches the work and an arc is estab lished both the machine output and the wire feed speed ramp to the weld settings throughout the start time The time period of ramping from the start set tings to the weld settings is called UPSLOPE WELD After upslope the power source output and the wire feed speed continue at the w
49. best matches the desired welding process The standard weld set shipped with the Power Wave C300 encompasses a wide range of common processes that will meet most needs If a special weld mode is desired contact the local Lincoln Electric sales representative All adjustments are made through the user interface Because of the different configuration options your system may not have all of the following adjustments Regardless of availability all controls are described in the following section See Figure B 4 Panel Controls Used DEFINITION OF WELDING MODES NON SYNERGIC WELDING MODES Non synergic welding mode requires all welding process variables to be set by the operator SYNERGIC WELDING MODES Synergic welding mode offers the simplicity of single knob control The machine will select the cor rect voltage and amperage based on the wire feed speed WFS set by the operator BASIC WELDING CONTROLS WELD MODE Selecting a weld mode determines the output charac teristics of the Power Wave power source Weld modes are developed with a specific electrode materi al electrode size and shielding gas For a more com plete description of the weld modes programmed into the Power Wave at the factory refer to the Weld Set Reference Guide supplied with the machine or avail able at www powerwavesoftware com WIRE FEED SPEED WFS In synergic welding modes synergic CV GMAW P WFS is the dominant control parameter The
50. de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PRECAUTIONS DE SURETE POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES A SOUDER A TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chass
51. disabled Use the SETUP menu and change P 4 to enable memory recall with the gun trigger Save a memory with memory buttons To save a memory press and hold the desired memo ry button for two seconds When the button is initially pressed the corresponding LED will illuminate After two seconds the LED will turn off Do not hold the button for more than 5 seconds when saving a user memory Note that memories may be locked with weld manager software to prevent accidental overwrite of the memo ries If an attempt is made to save a memory when memory saving is locked the message Memory save is Disabled will appear briefly in the MSP4 display RECALL PRESS 1 SECOND SAVE PRESS 2 SECONDS re JEL Recalling a memory To recall the selected memory press and quickly release the center knob After recalling a memory a message will briefly appear indicating that the select ed memory has been recalled The Memory LED will remain lit so that the user can quickly recall a different memory if needed POWER WAVE C300 LINCOLN 8 18 8 18 OPERATION LIMITS Limits allow the welder to adjust the welding proce dure 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 memo
52. e Disables the specified memory button s When a memory is disabled welding procedures can not be restored from or saved to that memory If an attempt is made to save or restore a dis abled memory a message will be displayed on the lower display indicating the memory number is disabled In multi head systems this parameter disables the same memory buttons on both feed heads This parameter can only be accessed using Power Wave Manager software Mode Select Panel Lock Selects between several Mode Select Panel lockout preferences When a Mode Select Panel selection is locked and an attempt is made to change that parameter a message will be dis played on the lower display indicating the parameter is locked All MSP Options Unlocked All adjustable parameters on the Mode Select Panel are unlocked All MSP Options Locked All knobs and buttons on the Mode Select Panel are locked Start and End Options Locked The Start and End parameters on the Mode Select Panel are locked all others are unlocked e Weld Mode Option Locked The weld mode cannot be changed from the Mode Select Panel all others Mode Select Panel settings are unlocked Wave Control Options Locked The Wave Control parameters on the Mode Select Panel are locked all others are unlocked Start End Wave Options Locked The Start End and Wave Control parameters on the Mode Select Panel are locked all others are unlocked Start End Mode Options Locked T
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54. e affect of adjusting trim or arc length To increase the arc length increase the SPD value at the Power Wave C300 to a value higher than the actual WFS Remember do not change the WFS at the spool gun decrease the arc length decrease the SPD value at the Power Wave C300 to a value lower than the actual WFS Remember The dialed in SPD value at the Power Wave C300 does not control the WFS at the spool gun Rather it is adjusting the Power Wave C300 synergic work point Therefore adjusting the SPD value will not change your actu al WFS at the spool gun WFS can only be changed at the spool gun PUSH PULL OPERATION Set the idle roll pressure on the wire drive between an indicator reading of 0 2 A recommended start point is 1 5 Configure the machine for push pull operation see parameter P 17 in the Set up Menu section Depending on the weld mode set the Voltage or Trim at the Power Wave C300 using the right con trol knob located on the upper case front panel The Wire Feed Speed WFS is set using the control knob on the Torch The left control knob on the Power Wave C300 is inactive The actual WFS being set at the torch is displayed on the Power Wave C300 All weld parameters normally available for the active weld mode are available during push pull operation Refer to the Operation Section of this manual POWER WAVE C300 LINCOLN B 27 B 28 OPERATION B 28 SETUP MENU FEA
55. e and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 4 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 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 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 In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the elect
56. e controls preventing the operator from making any changes This para meter can only be accessed using Power Wave Manager POWER WAVE C300 LINCOLN 1 OPTIONS ACCESSORIES STICK OPTIONS K875 ACCESSORY KIT 150 Amp 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 sam ple pack of mild steel electrode K857 K857 1 REMOTE OUTPUT Provides 25 ft 7 6m of remote cur CONTROL Requires K2909 1 6 pin to 12 pin adapter Portable current control provides the same dial range as the current control on the welder Consists of a 6 pin Amphenol connector which plugs into the remote control Amphenol 25 foot cable length TIG OPTIONS PTA 17 Premium Air Cooled Models K1782 2 PTA 17 TIG Torch 12 5 ft 3 8m 2 CABLES K1782 4 PTA 17 TIG Torch 25 ft 7 6m 2 CABLES PTA 26 Premium Air Cooled Models K1783 2 PTA 26 TIG Torch 12 5 ft 3 8m 2 CABLES K1783 4 PTA 26 TIG Torch 25 ft 7 6m 2 CABLES ACCESSORIES K870 FOOT AMPTROL Requires K2909 1 6 pin to 12 pin adapter K870 2 FOOT AMPTROL 12 pin plug connection Depress pedal to increase current Depressing pedal fully achieves maximum set current Fully raising the pedal finishes the weld and starts the Afterflow cycle K963 3 HAND AMPTROL Requires K2909 1 6 pin to 12 pin adapter rent control for TIG w
57. e dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas suppli er of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve outlet Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench Note if connecting to 100 CO cylinder insert reg ulator adapter between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seated for connection to the CO cylinder 5 Attach one end of the inlet hose to the outlet fitting of the flow regulator Attach the other end to the welding System shielding gas inlet Tighten the union nuts with a wrench 6 Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released 7 Standing to one side open the cylinder valve slowly a fraction of a turn When the cylinder pressure gage stops moving open the valve fully The flow regulator is adjustable Adjust it to the flow rate recommended for the procedure and process being used before making a weld POWER WAVE C300 LINCOLN 5 A a INSTALLATION LOADING SPOOLS OF WIRE A WARNING Keep hands hair clothing and tools away from rotat
58. e sure unused gun is positioned so electrode or tip will not contact metal case or other metal common to work Because the control circuitry senses each gun through its trigger leads weld parameters are displayed and adjustable for the last gun that was triggered 1 Pulling the trigger for the built in feeder gun Disables spool gun operation Changes the displays of the Power Wave C300 to correspond to feeder gun operation Closing feeder gun trigger starts feeder gun weld ing and makes both electrodes electrically HOT 2 Pulling SPOOL GUN Trigger Disables built in feeder gun operation Changes the displays of the Power Wave C300 to correspond to Spool Gun operation Closing spool gun trigger starts spool gun welding and makes both electrodes electrically HOT OPERATION B 26 3 eee with POWER WAVE C300 Install the spool gun per the installation instructions Turn the Power Wave C300 input power ON Make sure the machine is configured for spool gun operation see parameter P 17 in the Set up Menu sec tion Pull and release the trigger of the Spool Gun The Power Mig recognizes the spool gun as active and weld parameters are adjustable for welding with the Spool Gun Non Synergic Weld Modes Mode 5 Voltage is adjustable at the power source The right control knob on the power source will adjust the voltage that is displayed in the meter directly above it The left Display WFS AMPS on the Pow
59. econds the power source output and wire feed speed skips to the weld settings START The power source welds at the start WFS and voltage until the trigger is released OPERATION B 25 UPSLOPE During upslope the power source output and the wire feed speed ramp to the weld settings throughout the start time The time period of ramping from the start settings to the weld settings is called UPSLOPE WELD After upslope the power source output and the wire feed speed continue at the weld settings DOWNSLOPE As soon as the trigger is pulled the wire feed speed and power source output ramp to the crater settings throughout the crater time The time period of ramp ing from the weld settings to the crater settings is called DOWNSLOPE CRATER During CRATER the power source continues to sup ply output at the crater WFS and voltage BURNBACK When the trigger is released the wire feed speed is turned OFF and the machine output continues for the burnback time POSTFLOW Next the machine output is turned OFF and shielding gas continues until the post flow timer expires FIGURE B 15 4 Step Trigger 5 Start ON 5 2 ON o 6 2 5 9 Burnback ON 2 o 2 nc a a 5 D lt 2 D Idle Preflow Strike Start Upslope Weld Downslope Crater Burnback Postfow Idle 1 Shielding Gas i i off i 1 1 i 1 1 1 i 1 1 1 W
60. eed Gun Pot Disabled The wire feed speed is always controlled by the left front panel knob This setting is useful when the operator wishes to have wire feed speed settings recalled from memories and not have the potentiometer overwrite the setting Gun Pot Proc A When in procedure A the welding wire feed speed is controlled by the potentiometer on the push pull gun When in procedure B the welding wire feed speed is controlled by the left front panel knob This setting allows a fixed wire feed speed to be selected in procedure Remote Control Type This setup parameter was previously named Spool Push Pull This option selects the type of analog remote control being used Digital remote control devices those with a digital display are configured automatically Not all P 17 selections will be available on all machines When P 17 is used to configure the remote control to function in a specific process the remote will be ignored in other processes For example if P 17 TIG Amp Control the remote control will only function when TIG welding the remote will be ignored in other processes MIG stick and gouge Spool Gun Use this setting while MIG welding with a spool gun that uses a potentiometer used for wire feed speed control this setting is backward compatible with P 17 Gun Selection Standard Spool Push Pull Gun Use this setting wile MIG welding with a push pull gun that uses a potentiome ter for wire feed speed control
61. eed 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 Heplace the battery Type 852032 Weld and Arc Quality Problems General degradation of weld 1 Wire feed problem 1 Check for feeding problems Make mance sure proper gear ratio has been selected 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 ShieldinglS 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 6 Check for feeding problems Make sure proper gear ratio has been selected 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 C300 LINCOLN E TROUBLESHOOTING EM Obser
62. eld i Power 1 5 sec max Burrback Time Source stat ee EU iorum Output Crater Off WFS hl 2 2 POWER WAVE C300 LINCOLN 8 26 COLD FEED GAS PURGE SWITCH 1 Cold Feed and Gas Purge are com olo COLD FEED bined into a single spring centered tog gle switch To activate Cold Feeding hold the 17 GAS PURGE 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 Hold with toggle switch in the BACK position to acti vate Gas Purge and let the shielding gas flow The gas solenoid valve will energize but neither the power source output nor the drive motor will be turned on The Gas Purge switch is useful for setting the proper flow rate of shielding gas Flow meters should always be adjusted while the shielding gas is flowing SPOOL GUN OPERATION When the Power Wave C300 Gun is configured for Spool Gun Operation see parameter P 17 in the Set up Menu section the Power Wave C300 provides gun trigger switch transfer between the Built in gun or the spool gun for the same polarity welding with different wire and gas processes CAUTION Closing either gun trigger will cause the electrode of both guns to be electrically HOT B
63. eld settings BURNBACK As soon as the trigger is released the wire feed speed is turned OFF and the machine output contin ues for the burnback time POSTFLOW Next the machine output is turned OFF and shielding gas continues until the post flow timer expires FIGURE B 12 2 Step Trigger Start ON 5 Crater OFF 9 g 9 Burnback ON 5 2 2 g 1 D 5 Idle Preflow Run In Upslope Weld Burnback Postfow Idle Shielding Gas Off i i Start 1 Weld Power 1 5sec max Burnbac Time Source Output Off Weld WFS Run in POWER WAVE C300 LINCOLN 8 23 EXAMPLE 3 2 STEP TRIGGER Customized Arc Start Crater and Arc End Sometimes it is advanta geous 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 RUN IN After preflow time expires the power source regulates to the start output and wire is advanced towards the work piece at the Run In WFS If an arc is not estab lished within 1 5 seconds the power source output and wire feed speed skips to the weld settings START amp UPSLOPE As soon as the trigger i
64. elding 6 pin plug connection K963 4 HAND AMPTROL Provides 25 ft 7 6m of remote current control for TIG welding 12 pin plug connection POWER WAVE C300 LINCOLN C2 ACCESSORIES WIRE FEEDER OPTIONS K2447 1 05 PUSH PULL GUN Air Cooled 15 ft 4 5m Requires K2910 1 7 pin to 12 pin adapter a 2447 2 PYTHON PLUS PUSH PULL GUN Air Cooled 25 ft 7 6m Requires K2910 1 7 pin to 12 pin adapter K2447 3 PYTHON PLUS PUSH PULL GUN Air Cooled 50 ft 15 2m Requires K2910 1 7 pin to 12 pin adapter The Python family offers several options starting with the standard air cooled Python rated 200 amps at 10096 duty cycle The replaceable gooseneck of the Python can be interchanged with the full water cooled barrel and gas cup combination to achieve a rating of 400 amps 100 duty cycle The standard Python gun has separate wire and con duit power and gas connections The Python Plus air cooled models feature a Magnum backend that inte grates power gas and wire conduit into a single easy connection for direct plug into a Power Wave C300 K2704 2 COUGAR PUSH PULL GUN Air Cooled 25 ft 7 6m Requires K2910 1 7 pin to 12 pin adapter T K2704 3 COUGAR PUSH PULL GUN Air Cooled 50 ft 15 2 m Requires K2910 1 7 pin to 12 pin adapter K2874 1 PANTHER PUSH PULL GUN 15 ft 4 5m Requires K2910 1 7 pin to 12 pin adapter K2874 2
65. er Wave C300 will have 4 dashes to indi cate that the left control knob on the power source is inactive Wire Feed Speed is set at the Spool Gun The following procedure settings for Aluminum 4043 can be used as initial settings for making test welds to determine final settings Wire Dia WFS Setting Arc Voltage In mm Spool Gun Setting 030 8 mm 035 3 64 1 2 mm 4 Synergic Weld Modes The Power Wave C300 is designed to enable syner gic weld modes and synergic pulse processes with the spool gun The actual wire feed speed WFS of the spool gun must be measured and manually set on the Power Wave C300 as a work point for the Power Wave C300 SPD n synergic modes when the spool gun trigger is pulled an adjustable value for the SPD work point is displayed in the left meter The letters SPD are displayed in the right meter The left control knob adjusts the SPD value The right control knob is inactive Measure the actual WFS in inches per minute at the spool gun and set the SPD at the Power Wave C300 to match this value WFS can be measured by pulling the trigger of the spool gun and feeding wire for 6 seconds Measure the length of wire in inches that was fed and multi ply by 10 POWER WAVE C300 LINCOLN 7 OPERATION The Power Wave C300 is now configured and ready to weld in the synergic mode Adjustment of the SPD value from the set value has th
66. eration ss B 17 thru B 19 2 Step 4 Step Trigger Operation and B 20 thru B 25 Cold Feed Gas Purge B 26 Spool GUM Operation B 26 thru B 27 Set Up Feature an Very Nekene Laci ake B 28 thru B 36 inka D N dd gz Section C General Options KAR KA KA RA C 1 Stick Op rations x kalar dl C 1 TIG Options Accessories C 1 Wire Feed Options ria a kalin na a neda wazin C 2 thru C 3 viii TABLE OF CONTENTS Page 2 2 Section Safety sen Mill D 1 Routine Maintenance PHA D 1 Periodic Maintenance D 1 Calibration Specifications D 1 Troubleshooting ss k k nnnm Section E Salety Precautiofis doy telo e baka dea sus na ad a k da qan dana E 1 How to Use Troubleshooting E 1 Using Status LED and Error Fault Codes kk E 2 E 4 Troubleshooting Guide E 2 thru E 5 Error Fault Codes rrr rW r re r r rXaeer E 6 E 7 Wir
67. formance Set the pressure arm as follows See Figure A 6 Aluminum wires between 1 and 3 Cored wires between 3 and 4 Steel Stainless wires between 4 and 6 FIGURE A 6 FLUXCORE 32 ALUMINUM Aluminum wires Cored wires ARC wELDING D EM 56 Anc WELDING Steel Stainless wires POWER WAVE C300 LINCOLN 5 11 TIG WELDING Figure A 7 Tig uses Electrode Negative Polarity so for this appli cation 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 C300 s internal gas supply connection If required a foot amptrol can be connected to the remote control receptacle INSTALLATION SMAW WELDING Most SMAW welding procedures use Electrode Positive welding For these applications connect the stick electrode holder to the positive output stud and connect the work clamp to the negative output stud Some SMAW welding procedures use Electrode Negative Polarity For these applications connect the stick electrode holder to the negative output stud and connect the work clamp to the positive output stud FIGURE A 7 STUD POSITIVE STUD TO POSITIVE STUD WORK CLAMP 422 POWER CABLE TIG TORCH 2 TO NEGATIVE gt STUD Br GAS SUPPLY CON
68. ge level corre spondingly to maintain similar arc characteristics throughout the WFS range 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 pro portional to inductance Therefore increasing UltimArc Control greater than 0 0 results in a crisper arc more spatter while decreasing the UltimArc Control to less than 0 0 provides a softer arc less spatter OPERATION B 11 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 prefer ences When the voltage knob is rotated the display will show an upper or lower bar indicating if the voltage is above or below the ideal voltage Preset voltage above ideal voltage upper bar displayed Preset voltage at ideal voltage no bar displayed Preset voltage below ideal voltage lower bar displayed BASIC OPERATION eei 220 26 4 8 Less More M Longer Deposition Deposition Arc Arc CONTROL OPTIONS WELD MODE START OPTIONS DESCRIPTION Preflow Time Adjusts thetime thatshielding gas flows after the trigger is pulled and prior to feeding Run In sets the wire feed speed from the time the trigger is pulled until an arc is estab Run in WFS Stainless Ar Mix WIRE SIZE ELECTRODE AND GAS 0
69. general repairs The wire feeder controls Amperage Output Control and Arc Force dur ing SMAW welding During SMAW welding the wire drive remains idle BASIC OPERATION sel 194 TRIM LESS MORE OUTPUT OUTPUT AMPS AMPS OFF ON CC STICK MODES BERZA WODE Stick Soft 7018 Stick Crisp 6010 CONTROL OPTIONS START OPTIONS No arc starting options are active for SMAW Stick welding modes 2 gt setup Stick Crisp WELD MODE START OPTIONS UltimArc Control END OPTIONS UltimArc Control EFFECT RANGE ARC FORCE Soft 10 0 to Crisp 10 0 DESCRIPTION Arc Force adjusts the short cir cuit current for a soft arc or for a forceful driving arc It helps to prevent sticking and shorting of organic coated electrodes par ticularity globular transfer types such as stainless and low hydrogen Arc Force is espe cially effective for root pass on pipe with stainless electrode and helps to minimize spatter for certain electrodes and pro cedure as with low hydrogen etc END OPTIONS No arc ending options are active for SMAW Stick welding modes NOTE When a remote control pot such as a K936 1 or 2 Hand Amptrol is connected the left Control Knob adjusts the maximum arc amper age while the remote pot adjusts the actual arc amperage from minimum to the preset maxi mum POWER WAVE C300 LINCOLN 8 10 NON SYNERGIC GMAW AND FCAW WELDING In non s
70. gger is released During the Crater time the machine will ramp up or down from the Weld Procedure to the Crater Procedure The burnback time is the amount of time that the weld output continues after the wire stops feeding It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start Adjusts the time that shielding gas flows after the welding out put turns off C300 8 14 ALUMINUM SYNERGIC GMAW P PULSED MIG AND GMAW PP PULSE ON PULSE WELDING The Power Wave C300 can produce top quality alu minum 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 Use it to make welds with a stacked dime appearance similar to GTAW welds See Figure B 7 FIGURE B 7 The pulsing frequency is adjustable Changing the Modulation Frequency or UltimArc Control of the waveform changes the ripple spacing Faster travel speeds may be achieved by using higher values of Modulation Frequency See Figure B 8 and B 9p FIGURE 8 6 Modulation Frequency 10 Wide weld and ripple spacing slow travel speed FIGURE B 9 RI Modulation Frequency 10 Narrow weld and ripple spacing
71. ghout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Ethernet 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 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 Verify Network cable is not locat ed next to current carrying con ductors This would include input power cables and welding output cables CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE C300 LINCOLN Jequunu epoo jueuudinbe 9 499 664 e 404 juowyedeg 20m9 eu au 9 106911 s au sourd eunsojoue y jo euo uo 9090 1 024209 H31H3ANI ZOVIS sz
72. h as short as possible For additional Safety information regarding the electrode and work cable set up See the standard SAFETY INFORMATION located in the front of this Instruction Manual FIGURE A 3 POWER WAVE C300 LINCOLN 5 n INSTALLATION Ar SHIELDING GAS CONNECTION A 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 1 Safety in Welding and Cutting Published by the American Welding Society Customer must provide a cylinder of shielding gas a pressure regulator a flow control valve and a hose from the flow valve to the gas inlet fitting of the wire drive unit Connect a supply hose from the gas cylinder flow valve outlet to the 5 8 18 female inert gas fitting on the back panel of the Power Wave C300 MAXIMUM INLET PRESSURE IS 100 Psi 6 9 BAR Install the shielding gas supply as follows Secure the cylinder to prevent it from falling 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remov
73. h procedure A settings While welding quickly release then pull the gun trigger once The system will switch to procedure B settings Repeat to switch back to procedure A settings The procedure can be changed as many times as needed during the weld Release the trigger to stop welding The system will automatically return to procedure A settings Integral TrigProc When using a Magnum DS dual schedule gun or similar that incorpo rates a procedure switch in the gun trigger mechanism While welding in 2 step machine operation is identical to the External Switch selection When welding in 4 step additional logic prevents procedure A from being re selected when the trigger is released at step 2 of the 4 step weld sequence The machine will always operate in 2 step if a weld is made exclusive ly in procedure A regardless of the 2 4 step switch position this is intended to simplify tack welding when using a dual schedule gun in 4 step Stall Factor Adjustment This option allows the adjustment of the stall factor in Push Pull operation The stall factor con trols the stall torque of the push motor when using a push pull gun The wire feeder is factory set to not stall unless there is a large resistance to feeding wire The stall factor can be reduced to stall more easily and possibly prevent bird nesting However low stall factors can cause motor stalling during normal welding conditions which results in the wire burning back to the t
74. he Start End and Weld Mode Select parameters on the Mode Select Panel are locked all others are unlocked This parameter can only be accessed using Power Wave Manager software Setup Menu Lock Determines if the setup parameters can be modified by the operator without entering a pass code No The operator can change any set menu parameter without first entering the passcode even if the passcode is non zero default Yes The operator must enter the passcode if the passcode is non zero in order to change any setup menu parameters This parameter can only be accessed using Power Wave Manager software Set User Interface Passcode Prevents unauthorized changes to the equipment The default passcode is zero which allows full access A nonzero passcode will prevent unauthorized changes to memory limits saving to memory if P 502 Yes changes to setup parameters if P 505 Yes This parameter can only be accessed using Power Wave Manager software UI Master Lockout Locks all user interface controls preventing the operator from making any changes This para meter can only be accessed using Power Wave Manager software POWER WAVE C300 LINCOLN 5 36 OPERATION B 36 USER DEFINED PARAMETERS P 507 UI Clear All Memories Allows the operator to quickly set all memories to the default weld mode and welding parame ters Presently this option does not exist in any setup menu UI Master Lockout Locks all user interfac
75. he groove on the spindle POWER WAVE C300 LINCOLN 5 9 WIRE DRIVE CONFIGURATION See Figure A 4 Changing the Gun Receiver Bushing WARNING e ELECTRIC SHOCK can kill Turn the input power OFF at the welding power source before instal lation 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 sec onds after the gun trigger is released not operate with covers panels or guards removed or open Only qualified personnel should perform mainte nance work Tools required 1 4 hex key wrench Note Some gun bushings do not require the use of the thumb screw 1 Turn power off at the welding power source 2 Remove the welding wire from the wire drive 3 Remove the thumb screw from the wire drive 4 Remove the welding gun from the wire drive 5 Loosen the socket head cap screw that holds the connector bar against the gun bushing Important Do not attempt to completely remove the socket head cap screw 6 Remove the outer wire guide and push the gun bushing out of the wire drive Because of the pre cision fit light tapping may be required to remove the gun bushing 7 Disconnect the shielding gas hose from the gun bushing if required FIGURE A 5 OUTER WIRE GUIDE CONNECTOR BLOCK INSTALLATION A 9 8
76. hine 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 C300 LINCOLN D 1 E TROUBLESHOOTING ES HOW TO USE TROUBLESHOOTING GUIDE A 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 SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting
77. ing Diagram and Dimension Print Section F Parts Pages P 648 Series A INSTALLATION n TECHNICAL SPECIFICATIONS POWER WAVE C300 POWER SOURCE INPUT VOLTAGE AND CURRENT Duty Cycle Input Voltage 10 Input Amperes Idle Power Power Factor 1 Phase in paren Rated Output thesis 40 rating 208 230 400 460 575 30 28 16 14 11 K2675 2 1005 4 Tali 1 3 phase 50 60 Hz SITO 300 Watts Max 95 o rating includes 380V to 415V 41 37 NA NA NA fan on RATED OUTPUT Duty Cycle Volts RMS at Rated Amperes Amperes RMS GMAW Pulse SMAW TT TT TT TI 50 29 6 5 1 2 100 29 22 20 40 GTAW DC RECOMMENDED INPUT WIRE AND FUSE SIZES 1 INPUT INPUT AMPERE CORD SIZES TIME DELAY FUSE VOLTAGE RATING ON AWG SIZES mm OR BREAKER PHASE NAMEPLATE SIZE 2 AMPS FREQUENCY 208 1 50 60 208 3 50 60 230 1 50 60 230 3 50 60 400 3 50 60 460 3 50 60 575 3 50 60 1 Wire and Fuse Sizes based upon the U S National Electric Code and maximum output for 40 C 104 ambient 2 Also called inverse time or thermal magnetic circuit breakers circuit breakers that have a delay in tripping action that decreases as the magnitude of current increases 3 Type SO cord or similar in 30 C ambient POWER WAVE C300 LINCOLN 5 A INSTALLATION n WIRE FEED SPEED RANGE WIRE SIZE GMAW GMAW GMAW EMEN 0073 W RE SIZES
78. ing equipment not wear gloves when threading gt wire or changing wire spool Only qualified personnel should install use or service this equipment Loading 10 to 15 Ib 4 5 6 8kg Spools A K468 spindle adapter permits 8 203mm O D spools to be mounted on 2 51mm O D spindles 1 Squeeze the release bar on the retaining collar and remove it from the spindle 2 Place the spindle adapter on the spindle aligning the spindle brake pin with the hole in the adapter 3 Place the spool on the spindle and align the adapter brake tab with one of the holes in the back side of the spool An indicator mark on the end of the spindle shows the orientation of the brake tab Be certain the wire feeds off of the spool in the proper direction 4 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle Loading 16 to 44 Ib 7 3 20kg Spools 1 Squeeze the release bar on the retaining collar and remove it from the spindle 2 Place the spool on the spindle aligning the spindle brake pin with one of the holes in the back side of the spool An indicator mark on the end of the spin dle shows the orientation of the brake holding pin Be certain the wire feeds off of the spool in the proper direction 3 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages t
79. ip or rapid tack welds If you are experiencing bird nests check for other feeding problems before adjusting the stall factor The default value for the stall factor is 75 with a range of 5 to 100 POWER WAVE C300 LINCOLN 5 OPERATION B 31 USER DEFINED PARAMETERS Gun Offset Adjustment This option 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 Set the wire feed speed to 200 ipm Remove wire from the pull wire drive Hold an rpm meter to the drive roll in the pull gun Pull the trigger on the push pull gun Measure the rpm of the pull motor The rpm should be between 115 and 125 rpm If neces sary decrease the calibration setting to slow the pull motor or increase the calibration set ting to speed up the motor The calibration range is 30 to 30 with 0 as the default value time will be used in MIG and TIG When machine output on off is controlled via the upper right knob gas flow will not start until the tungsten touches the work Gas flow will continue when the arc is broken until the Postflow time expires When machine output on off is controlled via an arc start switch or foot Am
80. is du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place SAFETY 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 It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby weldi
81. justs 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 current Trim 1 50 Arc Length Long 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 current This results in a soft arc good for out of position welding FIGURE B 6 LIT UltimArc Control OFF Medium Frequency and Width UltimArc Control 10 0 Low Frequency Wide UltimArc Control 10 0 High Frequency Focused The Power Wave utilizes adaptive control to compensate for changes in the electrical stick out distance from the contact tip to the work piece while welding The Power Wave waveforms are optimized for a 5 8 to 3 4 stick out depending on the wire type and wire feed speed The adaptive behavior supports a range of stick outs from approximately 1 2 to 1 1 4 At low or high wire feed speeds the adaptive range may be less due to physical limitations of the welding process POWER WAVE C300 LINCOLN 8 13 STEEL AND STAINLESS GMAW P PULSED MIG WELDING BASIC OPERATION OPERATION B 13 op wFs amps 220 655 Deposition CONTROL OPTIONS More Deposition Arc WELD MODE WIRE SI
82. llowing shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers c computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement 9 the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures gt the time of day that welding or other activities are to be carried out LINCOLN B 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 Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit or equivalent Shielding
83. los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo 98 HRUSBHICRBRELTE 8 CMRI HRAEBGHRRAR ez 119 0A Sears dil s dle le Lily ques cil gal e 9 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftu
84. lowing Table E 1 TABLE E 1 Light Condition Main control board status light and Wiredrive 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 C300 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
85. ly pull and release the trigger 3 times To recall memory 1 quickly pull and release the trigger the number of user memories plus 1 Memories cannot be recalled while the system is welding Disabled The gun trigger cannot be used to recall user memories default Enabled The gun trigger can be used to recall user memories POWER WAVE C300 LINCOLN 5 30 OPERATION B 30 USER DEFINED PARAMETERS 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 Using a dual schedule gun which incorporates a procedure select switch in the trigger mecha nism pulling the trigger more than half way changes the procedure from A to B The possible values for this parameter are External Switch Procedure selection may only be performed at the memory panel or an external switch e g K683 Quick Trigger The selected procedure can be changed remotely by releasing and re pulling the trigger quickly while welding This feature is disabled in 4 Step trigger mode The external procedure switch is disabled To operate Select GUN on the memory panel Start the weld by pulling the gun trigger The system will weld wit
86. menu Wire Feed Speed Units This option selects which units to use for displaying wire feed speed English inches minute wire feed speed units default Metric meters minute wire feed speed units Arc Display Mode This option selects what value will be shown on the upper left display while welding Amps The left display shows Amperage while welding default WFS The left display shows Wire Feed Speed while welding Display Options This setup parameter was previously named Display Energy If the previous software revision had this parameter set to display energy that selection will remain This option selects the information displayed on the alphanumeric displayes while welding Not all P 3 selections will be available on all machines In order for each selection to be included in the list the power source must support that feature A software update of the power source may be needed to include the features Standard Display The lower displays will continue to show preset information during and after a weld default Show Energy Energy is displayed along with time in HH MM SS format Show Weld Score The accumulative weld score result is shown Recall Memory with Trigger This option allows a memory to be recalled by quickly pulling and releasing the gun trigger To recall a memory quickly pull and release the trigger the number of times that correspond to the memory number For example to recall memory 3 quick
87. n e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connec tion of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob lems of interference Screening of the entire welding installation may be considered for special applications 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment LINCOLN B vii for selecting a QUALITY product by Lincoln Electric We want you J hank OU to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On
88. n to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8
89. ng des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria 207 8 CT Ze OF OR Ez Ek HEEL 9 42274 ESAE Belle 9 28 7 MASP Ash 75 4274714 5357 E oe 4 1 sui e gal hia Giga 3 Ar ggill arin Le oi oaa Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig 8 nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e X7TTLZA V U AILINUD DORI YF gt e e 5 gt 49 UH Al audi uit qe juil alil e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas O XxJOA2 5 t tRQRUALZE
90. ng equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is compe tent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The fo
91. nt when the covers Lincoln Electric Field Service are removed facility for technical assistance Machine will not power up no lights 1 No Input Power 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 Input voltage is too low or too 2 Make certain that input voltage is 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 correct according to the Rating Plate located on the rear of the machine See Thermal LED is ON sec tion Possible short in output circuit If condition persists contact an 3a Input control board fault see authorized Lincoln Electric Field input control board error status Service facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE C300 LINCOLN ER TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Basic Machine Problems Continued 1 Improper fan operation 1 Check for proper fan operation Fan should run in a low sp
92. on F A N fan as needed Cooling fan runs when the output is energized 15 seconds following the strike of the welding arc and will continue to run 5 minutes following the end of the weld Thermostatically protected for safety and reliability Recessed connection panel for protection against accidental impact Ethernet connectivity via IP 67 rated ODVA compli ant RJ 45 connector Panel mounted Status and Thermal LED indicators facilitate quick and easy troubleshooting Potted PC boards for enhanced ruggednessrreliabili ly Enclosure reinforced with heavy duty aluminum extrusions for mechanical toughness Push Pull ready for welding aluminum Remote control Foot amptrol ready Waveform Control Technology for good weld appearance and low spatter even when welding nickel alloys 8 memories for easily selecting procedures Full sequence control for tailoring the weld from start to end Patented MAXTRAC 2 roll drive system Patent pending drive rolls improve traction on solid wire by up to 20 The precision machined rigid aluminum alloy frame results in maximum drive roll clamping pressure Patented split wire guides fully support the wire and virtually eliminate birdnesting tools required to change the drive rolls and wire guides POWER WAVE C300 LINCOLN OPERATION CASE FRONT CONTROLS FIGURE B 1
93. parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pe a e terra o E PORTED 2 8 9 8 8 5 2 RE BASIC CRM ML 845 era 2452 Je 84 mc uu 1 4 AAS ASA OAR gy outils JA dus ule Y jo e Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e 18 9 5 PA m TS BEL TEISRI 9159 248 42 AIX nig al gt ala e Wear eye ear and body protection e Prot jase los ojos
94. ptrol gas will begin flowing when the output is turned on and will con tinue flowing until the output is turned off and the Postflow time expires Crater Delay This option is used to skip the Crater sequence when making short tack welds If the trigger is released before the timer expires Crater will be bypassed and the weld will end If the trigger is released after the timer expires the Crater sequence will function normally if enabled Reset Consumable Weight Use this option to reset the initial weight of the consumable package Press the Right Button to reset the consumable weight This option will only appear with systems using Production Monitoring TIG Gas Control This option allows control over which gas solenoid actuates while TIG welding Valve manual 2 No solenoid will actuate while TIG welding gas flow is manually controlled by an external valve Solenoid auto The TIG solenoid will turn on and off automatically while TIG welding Notes Preflow is not available while TIG welding Postflow is available the same postflow POWER WAVE C300 LINCOLN 8 32 OPERATION B 32 USER DEFINED PARAMETERS Push Pull Gun Knob Behavior This option 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 sp
95. r in between the highest and the lowest weld mode num bers Once Weld Mode Search is displayed pressing the right pushbutton labeled Begin will start the search process START OPTIONS END OPTIONS END OPTIONS DESCRIPTION During the Crater time the machine will ramp up or down from the Weld Procedure to the Crater Procedure FFECT Crater Time 0 To 10 seconds During the search process pressing the right pushbut ton typically acts as a next button and the left push button typically acts as a back button Rotate the control knob then press the right pushbut ton to select relevant welding details such as welding process wire type wire size etc When the final selection is made the will automatically change to the weld mode found by the Weld Mode Search process Earlier products may not have this feature To acti vate this feature a software update may be needed from www powerwavesoftware com POWER WAVE C300 LINCOLN 8 17 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 UltimArc Controll etc immediately change the contents inside
96. rode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 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 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 6 Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES
97. rvice 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 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 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 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 C300 LINCOLN TROUBLESHOOTING ES Observe all Safety Guidelines detailed throughout this manual INPUT CONTROL BOARD 331 Peak input current limit Input current limit has been exceeded Typically indicates
98. s 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 5 LINCOLN 8 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY WELDING and CUTTING gt SPARKS 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 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been take
99. s even if the machine is not being used at high currents INPUT VOLTAGE SELECTION The POWER WAVE C300 automatically adjusts to work with different input voltages No reconnect Switches settings are required A WARNING e The POWER WAVE C300 ON OFF switch is not intended as a service disconnect for this equipment Only a qualified electrician should con nect 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 locat ed on the inside of the reconnect access door of the machine Failure to do so may result in bodily injury or death POWER CORD REPLACEMENT WARNING R 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 If the input power cord is damaged or needs to be replaced an input power connection block is located in the access panel under the wire spool ALWAYS CONNECT THE POWERWAVE GROUND ING LUG LOCATED INSIDE THE ACCESS PANEL TO A PROPER SAFETY EARTH GROUND FIGURE A 1 POWER WAVE C300 LINCOLN 5 ne INSTALLATION RECOMMENDED WORK CABLE SIZES F
100. s parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone
101. s pulled this starts preflow The Strike arc established Start time and Upslope parameters are used at the beginning of the weld sequence to establish a stable arc and provide a smooth transition to the weld settings OPERATION B 23 WELD After upslope the power source output and the wire feed speed continue at the weld settings CRATER amp DOWNSLOPE As soon as the trigger is released the wire feed speed and power source output ramp to the crater settings throughout the crater time The time period of ramping from the weld settings to the crater settings is called DOWNSLOPE BURNBACK After the crater time expires the wire feed speed is turned OFF and the machine output continues for the burnback time POSTFLOW Next the machine output is turned OFF and shielding gas continues until the post flow timer expires FIGURE B 13 2 Step Trigger Start ON Crater ON Burnback ON E 5 5 8 E Idle Preflow Strike U pslo pe Weld Downslope Burnback Postflow Idle 1 Shielding Gas Off Sterttime 4 1 1 i i i 1 Weld LI 1 Power 1 5 secmax Source Stacia Output Crateri a a 1 1 4 2 N i 1 1 1 1 i i Weld 1 i 1 WFS Crater Messe semis Run in i i i i I Crater time 1 LI LI
102. se leads This option will only appear in the list if the power source has a hardware selection option 67 pos polarity 2 An electrode sense lead is connected using positive polarity This is used by most GMAW welding procedures 67 neg polarity An electrode sense lead is connected using negative polarity This is used by most GTAW welding procedures and some Innershield procedures 67 amp 21 An electrode sense lead and work sense lead are connected Hardware Config The hardware determines the best remote sensing configuration This is applicable to MIG welding procedures only Voltage Sense Display Allows viewing of Voltage Sense Lead Selection to aid in troubleshooting The configuration is displayed as a text string on the lower display whenever the output is enabled This parameter is not saved on a power cycle but will be reset to False Show Test Modes Most power sources contain weld modes used for calibration and test purposes By default the machine does not include test weld modes in the list of weld modes that are available to the operator To manually select a test weld mode set this option to Yes When the power source is turned off and back on again the test modes will no longer appear in the mode list Test weld modes typically require the machine output to be connected to a grid load and cannot be used for welding View Diagnostic Diagnostics are only used for servicing or troubleshooting the Power Wave system
103. should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and positio
104. t be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment viii TABLE OF CONTENTS Page INStallatlOM Section Technical 1 2 Safety Precautions 3 Location LINO DD A 3 SACKING A N 3 Di lT D E 3 Input and Ground Connections 3 2222 2 20 0 1 1 1 3 High Frequency Protections reid are Dara Dar DV va Aa as Fette Si eet A 3 LUT COMMECUOM AE de ure 4 Input Fuse and Supply A 4 Input Voltage S lection tie 4 Power Cord Replacement sec jt idee A 4 Connection E A 5 Recommended Work Cable Sizes eene A 5 Remote Sense Lead Specifications Semi Automatic Welding A 5 pii E A 5 Cable ER 6 Cable Inductance and its Effects on 6 Shielding Gas Connections le d d
105. t the operation of RF controlled equipment which may result in bodily injury or damage to the equipment POWER WAVE C300 LINCOLN AMT INSTALLATION ii INPUT CONNECTION A WARNING 9 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 15 ft power cord is provided and wired into the machine Follow the power cord connection instruc tions For Single Phase Input Connect green lead to ground per National Electrical Code Connect black and white leads to power Wrap red lead with tape to provide 600V insulation For Three Phase Input Connect green lead to ground per National Electric Code Connect black red and white leads to power INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to Specification Section for recommended fuse 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 thermal magnetic circuit breakers Choose input and grounding wire size according to local or national electrical codes Using input wire sizes fuses or cir cuit breakers smaller than recommended may result in nuisance shut offs from welder inrush current
106. t to lift the POWER WAVE C300 with accessories attached to it Do not weld with the POWER WAVE C300 while the machine is suspended by the handles WARNING Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not operate machine while suspend ed when lifting FALLING EQUIPMENT can cause injury STACKING The POWER WAVE C300 cannot be stacked TILTING Place the machine directly on a secure level surface or on a recommended undercarriage The machine may topple over if this procedure is not followed INPUT AND GROUND CONNECTIONS Only a qualified electrician should connect the POWER WAVE C300 Installation should be made in accordance with the appropriate National Electrical Code all local codes and the information in this manual MACHINE GROUNDING The frame of the welder must be grounded A ground ter minal 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 HIGH FREQUENCY PROTECTION The EMC classification of the POWER WAVE C300 is Industrial Scientific and Medical ISM group 2 class A The POWER WAVE C300 is for industrial use only See Electromagnetic Compatibility EMC Safety Section Locate the POWER WAVE C300 away from radio con trolled machinery The normal operation of the POWER WAVE C300 may adversely affec
107. this setting is backward compatible with P 17 Gun Selection PushPull TIG Amp Control Use this setting while TIG welding with a foot or hand current control device Amptrol While TIG welding the upper left knob on the User Interface sets the maximum cur rent obtained when the TIG amp control is at its maximum setting Stick Gouge Rem Use this setting while stick welding or gouging with a remote output control device While stick welding the upper left knob on the User Interface sets the maximum current obtained when the stick remote is at it s maximum setting While gouging the upper left knob is disabled and the gouging current is set on the remote control All Mode Remote This setting allows the remote control to function in all weld modes which is how most machines with 6 pin and 7 pin remote control connections operate This setting was provided so that customers with a mix of Lincoln Electric equipment can have consistent remote control behavior across all of their equipment N American default Joystick MIG Gun Use this setting while MIG welding with a push MIG gun with a joystick control Stick TIG and gouge welding currents are set at the User Interface European default Display Trim as Volts Options This option determines how trim is displayed False The trim is displayed in the format defined in the weld set default True All trim values are displayed as a voltage POWER WAVE C300 LINCOLN
108. tup 200 LO 180 WELD WFS WELD MODE START OPTIONS UltimArc Control 9 END OPTIONS Parameter Name If the passcode has been set to zero 0000 SETUP will illuminate on the MSP4 panel and the display will show the following Four items show on the MSP4 panel Memory Value High Limit Low Limit Parameter Name One of these items will flash to indicate which item will change when the MSP4 encoder is rotated Press the right button on the MSP4 panel to select the item to change 200 HI 200 10 180 C sene WELD WFS START 5 enp options WELD MODE UltimArc Control Press to select item to change Rotate to Change Value The Limits Setup menu shows a list of all parameters available for the weld mode stored in the memory chosen For example if limits are being set for a stick SMAW mode parameters such as Run in WFS and Postflow will not appear To lock a parameter to a specific value that can not be changed set the high and low limits to the same value OPERATION B 19 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 Press the left MSP4 for button YES to save and enable the limits and exit Press the right MSP4 button NO
109. user adjusts WFS according to factors such as wire size penetration requirements heat input etc The Power Wave then uses the WFS setting to adjust the voltage and current according to settings contained in the Power Wave In non synergic modes the WFS control behaves like a conventional power source where WFS and voltage are independent adjustments Therefore to maintain proper arc characteristics the operator must adjust the voltage to compensate for any changes made to the WFS AMPS In constant current modes this control adjusts the welding current VOLTS In constant voltage modes this control adjusts the welding voltage TRIM In pulse synergic welding modes the Trim setting adjusts the arc length Trim is adjustable from 0 50 to 1 50 1 00 is the nominal setting and is a good start ing point for most conditions ULTIMARC CONTROL UltimArcTM Control allows the operator to vary the arc characteristics from soft to crisp UltimArc Control is adjustable from 10 0 to 10 0 with a nominal setting of 0 0 POWER WAVE C300 LINCOLN Bra OPERATION CASE FRONT CONTROLS USED OO WIRE FEED SPEED WFS al M MORE AMPS AMPS DUAL PROCEDURE MEMORY PANEL OPERA TION 15 VOLTS 12 TRIM OUTPUT Gunes OFF CT setup POWER WAVE C300 LINCOLN 8 9 OPERATION B 9 SMAW STICK WELDING SMAW is most often used for outdoor construction pipe welding and
110. ve all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Weld and Arc Quality Problems Continued Wire burns back to tip at the end of 1 Burnback Time 1 Reduce burnback time and or the weld work point Machine output shuts down during a 1 Secondary current limit has 1 Adjust procedure or reduce load 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 Calibrate secondary current and voltage Excessively long and erratic arc 1 Check for feeding problems Make sure proper gear ratio has been selected 3 Calibrate secondary current and voltage CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER WAVE C300 LINCOLN E TROUBLESHOOTING EB Observe all Safety Guidelines detailed throu
111. ynergic modes the WFS control is similar to a conventional CV power source where WFS and volt age are independent adjustments Therefore to main tain the arc characteristics the operator must adjust the voltage to compensate for any changes made to the WFS OPERATION B 10 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 pro portional to inductance Therefore increasing UltimArc Control greater than 0 0 results in a crisper arc more spatter while decreasing the UltimArc Control to less than 0 0 provides a softer arc less spatter BASIC OPERATION MODES 5 AND 6 se 800 25 3 LESS MORE LESS MORE WFS WFS VOLTS VOLTS CONTROL OPTIONS WELD MODE PROCESS WELD MODE GMAW STANDARD CV GMAW POWER MODE FCAW STANDARD CV 6 MODE 40 252501 54 LESS MORE LESS MORE WES WFS VOLTS VOLTS START OPTIONS DESCRIPTION EFFECT Preflow Time Adjusts the time that shielding gas flows after the trigger is pulled and prior to feeding wire Run In sets the wire feed speed from the time the trigger is pulled until an arc is estab lished The Start Procedure controls the WFS and Volts for a speci fied time at the beginning of the weld During the start time the machine will ramp up or down from the Start Procedure to

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