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Lincoln Electric POWER WAVE IM10040 manual

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Table of contents for the manual

  • Page 1

    • 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 • World's Leader in Welding and Cutting Products • PO WER W A VE ® C300 OPERA TOR’S MANUAL IM10040 February, 2011 Safety Depends on You Lincoln arc welding an[...]

  • Page 2

    !*- )"$) FEM;H;:;GK?FC;DJ 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ______________________________________[...]

  • Page 3

    -- 4.97D8KHD 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your sk[...]

  • Page 4

    !*- ' /-$'' 4 FEM;H;:;GK?FC;DJ 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with t[...]

  • Page 5

    +-R0/$*). ._- /R Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: .TH;JS+EKH.EK:7=;'bH9 1. Protegez-vous contre la secousse électrique: a. Les cir[...]

  • Page 6

    /#$..(+' *0( )/$.0. !*-] ^(#$) .*)' 4 L L .! /4 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 comp[...]

  • Page 7

    /#$..(+' *0( )/$.0. !*-] ^(#$) .*)' 4 L? L? .! /4 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 pre[...]

  • Page 8

    L?? L?? Thank Y ou for selecting a ,0'$/4 product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! -;7:J>?I*F;H7JEHI (7DK7B9ECFB;J;BO before attempting to use this equipment. Save this manual and keep it handy [...]

  • Page 9

    L??? L??? / ' *!*)/ )/. Page $DIJ7BB7J?ED [...]

  • Page 10

    Page (7?DJ;D7D9; .;9J?ED Safety Precautions [...]

  • Page 11

     $)./ '' /$*) +*2 -21 V  / #)$' .+ $!$ /$*).+*2 -2  1 V - *(( ) $)+0/2$-  )!0. .$5 .  $)+0/ 1*'/"  +#.  !- ,0 )4 208/1/50/60 208/3/50/60 230/1/50/60 230/3/50/60 40[...]

  • Page 12

     $)./ '' /$*) +*2 -21 V  +#4.$'$( ).$*). / (+ - /0- -)" . # $"#/ 18.8in (478mm) (* ' K2675-2 2$/# 14.00in (356mm)  +/# 27.4in (697mm) 2 $"#/ 100.0lbs (47.6kg)  *+ -/$)"/ (+ -/0- -)" Environmentally Harde[...]

  • Page 13

     $)./ '' /$*) +*2 -21 V      J>?I ;DJ?H; ?DIJ7BB7J?EDI;9J?ED 8;<EH; OEKIJ7HJ ?DIJ7BB7 J?ED ' /-$.#*&97DA?BB 3  (&2 +/&$!$  * ,-)(( &am[...]

  • Page 14

     $)./ '' /$*) +*2 -21 V  $)+0/*)) /$*) *DBO 7 GK7B?<?;: ;B;9JH?9?7D I>EKB: 9EDD;9J J>; ?DFKJ B;7:I JE J>; +*2 - 21 V  EDD;9J?EDI I>EKB: 8; C7:; ?D 799EH:7D9; M?J> 7BB BE97B 7D: D[...]

  • Page 15

     $)./ '' /$*) +*2 -21 V  - *(( )  2*-& ' .$5 .!*- -2 '$)" 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 cabl[...]

  • Page 16

     $)./ '' /$*) +*2 -21 V  3 3 4 4 2 2 1 1 3 3 4 4 2 2 1 1 !KD9J?ED 4-pin trigger con- nector for push- only guns. +$) 1 2 3 4 2?H?D= Supply Voltage for Dual Procedure Dual Procedure Input Trigger Input Supply Voltage for Trigger /'  !$"0-  ?[...]

  • Page 17

     $)./ '' /$*) +*2 -21 V  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 counte[...]

  • Page 18

     $)./ '' /$*) +*2 -21 V  '*$)".+**'.*!2$- U&;;F>7D:I>7?H9BEJ>?D=7D:JEEBI7M7O<HEC HEJ7J?D=;GK?FC;DJ UEDEJM;7H=BEL;IM>;DJ>H;7:?D= M?H;EH9>7D=?D=M?H;IFEEB U*DB[...]

  • Page 19

     $)./ '' /$*) +*2 -21 V  2$- -$1 *)!$"0- /$*) (See Figure A.4) >7D=?D=J>;"KD-;9;?L;HKI>?D= ' /-$.#*&97DA?BB U  /KHD J>; ?DFKJ FEM;H *!! 7J J>; M;B:?D= FEM;H IEKH9; 8;&l[...]

  • Page 20

     $)./ '' /$*) +*2 -21 V  "0)0.  The Magnum 350PRO is the recommended gun for the POWER WAVE® C300. Refer to the Magnum 350PRO’s operators manual for installation instruc- tions. ! $)" ' /-* ) -& %0./( )/ 1. Turn the [...]

  • Page 21

     $)./ '' /$*) +*2 -21 V  /$"2 '$)" (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 shou[...]

  • Page 22

     *+ - /$*) +*2 -21 V  U  ' /-$ .#*& ) &$'' 0DB;II KI?D= *' !  <;7 JKH;M>;D <;;:?D=M?J>=KD JH?= =;H J>; ;B;9JHE:; 7D: :H?L; C;9>7D?IC 7H; 7BM7OI ;B;9JH? 97BBO[...]

  • Page 23

     *+ - /$*)  +-*0/ .-$+/$*) 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. />;+EM;H27L;[...]

  • Page 24

     *+ - /$*)   .$")!  /0- . 'E7:;:M?J>.J7D:7H:!;7JKH;I • Multiple process DC output range: 5 - 300 Amps. • 200 – 600 VAC, 1/3 phase, 50-60Hz input power. • New and Improved Line Voltage Compensation holds the output constant over wide input voltage fluctuations. • Utilizes next generation [...]

  • Page 25

     *+ - /$*)  . !-*)/*)/-*'. All operator controls and adjustments are located on the case front of the Power Wave. .;;!?=KH; ' !/$.+'4 Shows wire feed speed or amper- age,  ' !/&)* - Adjusts value in left display. ($)?[...]

  • Page 26

     *+ - /$*)  +*2 -21 V . &*)/-*'.  /# -) /*)) /*-  +*2 -*- ".*)) /$*)"(2)!2 "7IEDD;9J?ED"/2 1 2 3 4 1 2 3 4 !$"0- [...]

  • Page 27

     *+ - /$*)  $)/ -)' *)/-*'. E:; .+$)' -& 2$- -$1 +- ..0- -(  /#0(.- 2!*-. 0-$)"/# 2 '$)""0) "0)0.#$)"   .*& / #  ?[...]

  • Page 28

     *+ - /$*)  (&$)"   2 ' 2$/# 2  1 !*-( / #)*'*"4 +*2 -.*0- . (&$)"2 ' />; I;HL?9;78?B?JO E< 7 FHE:K9J EH IJHK9JKH; KJ?B?P ?D= J>; M;B:?D= FHE=H7CI ?I 7D: CKIJ 8; J>; IEB; H;IFED[...]

  • Page 29

     *+ - /$*)  +*2 -21 V START OPTIONS END OPTIONS SETUP WELD MODE UltimArc™ Control LESS AMPS MORE AMPS OUTPUT OFF OUTPUT ON + + AMPS WIRE FEED SPEED (WFS) VOLTS TRIM ST ART OPTIONS END OPTIONS SETUP WELD MODE UltimArc™ Control LESS AMPS MORE AMPS OUTPUT OFF OUTPUT ON + + AMPS WIRE FEED SPEED (WFS) VOL TS[...]

  • Page 30

     *+ - /$*)  .( 2./$&2 '$)" SMAW is most often used for outdoor construction, pipe welding and general repairs. The wire feeder controls Amperage, Output Control and Arc Force dur- ing SMAW welding. During SMAW welding the wire drive remains idle. )*/  When a remote control pot such as a K93[...]

  • Page 31

     *+ - /$*)  )*).4) -"$ "( 2 ) ! 2 2 '$)" In non-synergic 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 com[...]

  • Page 32

     *+ - /$*)  "( 2($".4) -"$2 '$)" 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 c[...]

  • Page 33

     *+ - /$*)  +*2 -21 V ./ '  )./ $)' ...4) -"$"( 2 ++0'. ($"2 '$)" Trim .50 Arc Length S ho rt Trim 1 .00 Arc L ength M ed ium Trim 1.50 Arc Length L ong T rim .5 0 Arc Length S ho rt T rim 1 .0 0 Arc L en g t h [...]

  • Page 34

     *+ - /$*)  ./ '  ) ./ $)' .. "( 2+ +0'. ($"2 '$)" +*2 -21 V START OPTIONS END OPTIONS SETUP WELD MODE UltimArc™ Control Less Deposition More Deposition Shorter Arc Longer Arc + + AMPS WFS VOLTS TRIM 220 1.06 STEEL .035&quo[...]

  • Page 35

     *+ - /$*)  +*2 -21 V '0($)0( .4) -"$ "( 2+ +0'.  ($") "( 2++ +0'. *)+0'. 2 '$)" The Power Wave® C300 can produce top quality alu- minum welds with excellent appearance, little spatter and[...]

  • Page 36

     *+ - /$*)  +*2 -21 V '0($)0( "( 2+  +0'.  ($" ) "( 2 ++ +0'.  *) +0'.  2 '$)" START OPTIONS E ND OPTIONS SETUP WELD MODE UltimArc™ Control Less Deposition More Deposition Shorter Arc Longer Arc [...]

  • Page 37

    2 '(* . -#$)" The Weld Mode Search feature allows the selection of a welding mode based on certain criteria (wire size, process type, etc.). . -#$)"!*-  2 '(* To search for a mode, turn the control knob until “Weld Mode Search” is displayed. This will appear in between the highest[...]

  • Page 38

     *+ - /$*)  0' +-* 0- ( (*- 4 + ) ' *+ - /$*) The Dual Procedure/Memory Panel performs three functions: U2;B:FHE9;:KH;I;B;9J?ED U(;CEHOI7L;7D:H;97BB U'?C?JII;JJ?D= There are two procedure memories (  and  ) and eight user memories (1-8). +HE9;:KH;?[...]

  • Page 39

     *+ - /$*)  To set limits, press the desired memory button 1-8 and hold for 5 seconds. Release the memory button when the LED begins to blink rapidly and the MSP4 displays "Memory X Set Limits" as shown below. +*2 -21 V '$($/. Limits allow the welder to adjust the welding proce- dure on[...]

  • Page 40

     *+ - /$*)  +*2 -21 V 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. If the passcode has been set to zero (0000), SETUP will illuminate on the MSP4 panel an[...]

  • Page 41

     *+ - /$*)  +*2 -21 V ./ +  ./ + /-$"" - *+ - /$*) 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 inte[...]

  • Page 42

     *+ - /$*)  +*2 -21 V 3(+' ./ +/-$"" - 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, +- !'*2 Shielding gas begins to flo[...]

  • Page 43

     *+ - /$*)  +*2 -21 V 3(+'     ./ + /-$"" - 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 desir[...]

  • Page 44

     *+ - /$*)  +*2 -21 V 2 ' After upslope, the power source output and the wire feed speed continue at the weld settings. -/ -*2).'*+  As soon as the trigger is released, the wire feed speed and power source output ramp to the crater settings throughout the crater ti[...]

  • Page 45

     *+ - /$*)  +*2 -21 V Shielding Gas I dle Pre flow Strike Wel d Burn ba ckPost flowIdle WFS On Off Run -in Off Weld Off Weld Arc Established Trigger Pulled Trigger Released 4 Step Trigg er Start = O FF Crater = OFF Bu rnback = OFF 1.5 sec ma x. Start Cra ter Power Source Output Cra ter Trigger Pulled [...]

  • Page 46

     *+ - /$*)  +*2 -21 V 3(+'     ./ + /-$"" - 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 alu[...]

  • Page 47

     *+ - /$*)  3. *F;H7J?EDM?J>+*2 -21 V • 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 + in the Set-up Menu sec- tion). • Pull and release the[...]

  • Page 48

     *+ - /$*)  +*2 -21 V • 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 the 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[...]

  • Page 49

     *+ - /$*)  +*2 -21 V . / 0+!  /0- .( )0 (See Figure B.16) 1. To access the set-up menu, press the -?=>J and ';<J buttons of the (.+ panel simultaneously. )EJ; that the set-up menu cannot be accessed if the system is welding, or if there is a fault (The sta- tus '  is[...]

  • Page 50

     *+ - /$*)  +*2 -21 V +7H7C;J;H ;<?D?J?ED N?J.;JKF(;DK +  This option is used to exit the setup menu. When P.0 is displayed, press the Left Button to exit the setup menu. +  2?H;!;;:.F;;:0D?JI This option selects which units to use for displaying wire feed speed. Engli[...]

  • Page 51

     *+ - /$*)  +*2 -21 V +7H7C;J;H ;<?D?J?ED +  +HE9;:KH;>7D=;(;J>E: 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 r[...]

  • Page 52

     *+ - /$*)  +*2 -21 V +7H7C;J;H ;<?D?J?ED +  "KD*<<I;J:@KIJC;DJ 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 me[...]

  • Page 53

     *+ - /$*)  +*2 -21 V +7H7C;J;H ;<?D?J?ED +  +KI>+KBB"KD&DE8;>7L?EH 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 gu[...]

  • Page 54

     *+ - /$*)  +*2 -21 V +7H7C;J;H ;<?D?J?ED +  H9.J7HJ'EII HHEH/?C; 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 [...]

  • Page 55

     *+ - /$*)  +*2 -21 V +7H7C;J;H ;<?D?J?ED +  1?;M!7J7B'E=I 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 Cont[...]

  • Page 56

     *+ - /$*)  +*2 -21 V +7H7C;J;H ;<?D?J?ED +  (;CEHOKJJED?I78B; 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[...]

  • Page 57

     *+ - /$*)  +*2 -21 V +7H7C;J;H ;<?D?J?ED +  0$B;7HBB(;CEH?;I 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. +  0$(7IJ;H'E9AEKJ Locks all[...]

  • Page 58

      ..*-$ .  +*2 -21 V *+/$*).  ..*-$ . ./$&*+/$*). &  ..*- 4&$/  CF 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, electr[...]

  • Page 59

      ..*-$ .  2$- !  -*+/$*). & +4/#*)+'0. +0.#+0'' "0) Air-Cooled, 15 ft.(4.5m). Requires K2910-1, 7-pin to 12-pin adapter. & +4/#*)+'0. +0.#+0'' "0) Air-Cooled, 25 ft.(7.6m). Requires K2910-1, 7-pin to[...]

  • Page 60

     ($)/ ))  +*2 -21 V .! /4 +- 0/$*). 2 -)$)" ' /-$.#*&97DA?BB U E DEJ EF;H7J; M?J> 9EL;HI H;CEL;: U /KHD E<< FEM;H IEKH9; 8;<EH; ?DIJ7BB?D=EHI;HL?9?D= U E DEJ JEK9> ;B;9JH?97BBO >EJ[...]

  • Page 61

     /-*0' .#**/$)"  +*2 -21 V If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your 'E97B'?D9EBDKJ>EH?P;:!?;B:.;HL?9;!79?B?JO for technical troubleshooting assistance before you proceed. 0/$*) This[...]

  • Page 62

     /-*0' .#**/$)"  +*2 -21 V If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your 'E97B'?D9EBDKJ>EH?P;:!?;B:.;HL?9;!79?B?JO for technical troubleshooting assistance before you proceed. 0/$*) 0.$)[...]

  • Page 63

     /-*0' .#**/$)"  +*2 -21 V Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your 'E97B'?D9EBDKJ>EH?P;:!?;B:.;HL?9;!79?B?JO for technical t[...]

  • Page 64

     /-*0' .#**/$)"  +*2 -21 V Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your 'E97B'?D9EBDKJ>EH?P;:!?;B:.;HL?9;!79?B?JO for technical t[...]

  • Page 65

     /-*0' .#**/$)"  +*2 -21 V *8I;HL;7BB.7<;JO"K?:;B?D;I:;J7?B;:J>HEK=>EKJJ>?IC7DK7B If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your 'E97B'?D9EBDKJ>EH?P;:!?;B:.;H[...]

  • Page 66

     /-*0' .#**/$)"  +*2 -21 V Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your 'E97B'?D9EBDKJ>EH?P;:!?;B:.;HL?9;!79?B?JO for technical t[...]

  • Page 67

     /-*0' .#**/$)"  +*2 -21 V Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your 'E97B'?D9EBDKJ>EH?P;:!?;B:.;HL?9;!79?B?JO for technical t[...]

  • Page 68

     /-*0' .#**/$)"  +*2 -21 V Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your 'E97B'?D9EBDKJ>EH?P;:!?;B:.;HL?9;!79?B?JO for technical t[...]

  • Page 69

    ! $"-(. ! +*2 -21 V )*/  This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a repl[...]

  • Page 70

    ! $( ).$*)+-$)/ ! +*2 -21 V 18.80 6.93 13.94 27.43 24.04 18.80 6.93 13.94 2 7.43 24.04[...]

  • Page 71

    )*/ . +*2 -21 V[...]

  • Page 72

    )*/ . +*2 -21 V[...]

  • Page 73

    2 -)$)"  1$.* +- 0$*)  // )/$*) 2 -)0)"  / )Q[* .F7D?I> !H;D9> ";HC7D +EHJK=K;I; %7F7D;I; >?D;I; &EH;7D H78?9 READ AND UNDERST AND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTE[...]

  • Page 74

    2 -)$)"  1$.* +- 0$*)  // )/$*) 2 -)0)"  / )Q[* .F7D?I> !H;D9> ";HC7D +EHJK=K;I; %7F7D;I; >?D;I; &EH;7D H78?9 LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁ TICAS DE SEGURANÇA DO EMPREGADOR. l Keep your head o ut of f umes. [...]

  • Page 75

    • 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 • World's Leader in Welding and Cutting Products •[...]