Lincoln Electric Welder IM10040 User Manual

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IM10040

February, 2011

POWER WAVE C300

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.

OPERATOR’S MANUAL

• 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 WEBꢀSITE: www.lincolnelectric.com

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SAFETY

ARC RAYS can burn.

ELECTRIC ShOCK can

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.

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.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

4.c. 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.

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:

FuMES AND GASES

can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

fumes and gases. When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

• AC Welder with Reduced Voltage Control.

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.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. 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.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

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 TLV limits.

3.g. Never dip the electrode in water for cooling.

3.h. 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.

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-

ucts.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

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

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.

5.f. Also see item 1.b.

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iii

SAFETY

WELDING and CuTTING

SPARKS can

cause fire or explosion.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

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.

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

Remember that welding sparks and hot

materials from welding can easily go through small cracks

and openings to adjacent areas. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

6.b. 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.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

6.c. 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.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken 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).

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. 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.

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f. 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.

FOR ELECTRICALLY

powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

6.g. 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.

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 the U.S. National

Electrical Code and the manufacturer’s recommendations.

6.h. Also see item 1.c.

6.I. 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.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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SAFETY

5. Toujours porter des lunettes de sécurité dans la zone de

PRÉCAuTIONS DE SÛRETÉ

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

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:

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

b. Faire trés 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 couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

PRÉCAuTIONS DE SÛRETÉ POuR

LES MAChINES À SOuDER À

TRANSFORMATEuR ET À

REDRESSEuR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

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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 welding 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 following 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

g) 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;

h) the time of day that welding or other activities are to be carried out.

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SAFETY

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 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 position, 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

_________________________

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-

uct standard for arc welding equipment.”

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vii

for selecting a QuALITY product by Lincoln Electric. We want you

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Thank 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 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. 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 WEbꢀSITE 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 must be followed exactly to avoid serious personal injury or loss of life.

CAuTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

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viii

TAbLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications ...............................................................................................A-1, A-2

Safety Precautions ...............................................................................................................A-3

Location, Lifting.............................................................................................................A-3

Stacking ........................................................................................................................A-3

Tilting.............................................................................................................................A-3

Input and Ground Connections .....................................................................................A-3

Machine Grounding.......................................................................................................A-3

High Frequency Protection............................................................................................A-3

Input Connection ..................................................................................................................A-4

Input Fuse and Supply Wire..........................................................................................A-4

Input Voltage Selection .................................................................................................A-4

Power Cord Replacement.............................................................................................A-4

Connection Diagram .....................................................................................................A-5

Recommended Work Cable Sizes ................................................................................A-5

Remote Sense Lead Specifications, Semi Automatic Welding.....................................A-5

Polarity ..........................................................................................................................A-5

Cable Connections...............................................................................................................A-6

Cable Inductance and its Effects on Welding................................................................A-6

Shielding Gas Connections..................................................................................................A-7

Loading Spool Wire..............................................................................................................A-8

Wire Drive Configuration ......................................................................................................A-9

Procedure to Install Drive Rolls and Wire Guides.........................................................A-9

Gun Used ...........................................................................................................................A-10

Feeding Electrode and Brake Adjustment...................................................................A-10

Drive Roll Pressure Setting.........................................................................................A-10

TIG Welding .......................................................................................................................A-11

SMAW Welding...........................................................................................................A-11

________________________________________________________________________________

Operation.........................................................................................................................Section b

Safety Precautions ...............................................................................................................B-1

Graphic Symbols...........................................................................................................B-1

Power-Up Sequence.....................................................................................................B-1

Duty Cycle.....................................................................................................................B-1

Product Description..............................................................................................................B-2

Recommended Processes and Equipment..........................................................................B-2

Equipment Limitations..........................................................................................................B-3

Common Equipment Packages.....................................................................................B-3

Design Features............................................................................................................B-3

Case Front Controls .............................................................................................................B-4

Case Back Controls..............................................................................................................B-5

Internal Controls...................................................................................................................B-6

Making a Weld with Waveform Technology Power Sources................................B-7 thru B-16

Procedure/Memory Panel Operation..................................................................B-17 thru B-19

2 Step - 4 Step Trigger Operation and Graphics................................................B-20 thru B-25

Cold Feed/Gas Purge Switch.............................................................................................B-26

Spool Gun Operation..........................................................................................B-26 thru B-27

Set-Up Feature Menu ........................................................................................B-28 thru B-36

________________________________________________________________________________

Accessories.....................................................................................................Section C

General Options / Accessories..............................................................................C-1

Stick Operations ....................................................................................................C-1

TIG Options / Accessories.....................................................................................C-1

Wire Feed Options...............................................................................................C-2 thru C-3

________________________________________________________________________

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TAbLE OF CONTENTS

Page

Maintenance ....................................................................................................Section D

Safety Precautions...............................................................................................................D-1

Routine Maintenance ...........................................................................................................D-1

Periodic Maintenance...........................................................................................................D-1

Calibration Specification.......................................................................................................D-1

________________________________________________________________________________

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Using Status LED and Error Fault Codes.....................................................................E-2, E-4

Troubleshooting Guide.............................................................................E-2 thru E-5

Error Fault Codes .........................................................................................................E-6, E-7

________________________________________________________________________________

Wiring Diagram and Dimension Print............................................................Section F

________________________________________________________________________

Parts Pages ................................................................................................................P-648 Series

_______________________________________________________________________________

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A-1

INSTALLATION

TEChNICAL SPECIFICATIONS - POWER WAVE® C300

POWER SOuRCE-INPuT VOLTAGE AND CuRRENT

Input Amperes

(1 Phase in paren-

thesis)

Input Voltage ± 10%

Model

Duty Cycle

Power Factor @

Rated Output

Idle Power

30/28/16/14/11

(53/48/NA/NA/NA)

23/21/12/11/9

(41/37/NA/NA/NA)

40% rating

208/230/400*/460/575

1/3 phase 50/60 Hz

(* includes 380V to 415V)

K2675-2

300 Watts Max.

(fan on)

.95

100% rating

RATED OuTPuT

Volts (RMS) at Rated Amperes

Process

Duty Cycle

40%

Amperes (RMS)

GMAW

GMAW-Pulse

FCAW

26.5

31.2

300

250

280

225

300

250

100%

40%

SMAW

100%

40%

GTAW-DC

100%

RECOMMENDED INPuT WIRE AND FuSE SIzES ¹

TIME DELAY FuSE

OR bREAKER

INPuT AMPERE

RATING ON

NAMEPLATE

INPuT

CORD SIzES

VOLTAGE /

PhASE/

FREQuENCY

AWG SIzES (mm )

SIzE (AMPS)

6 (16)

8 (10)

6 (16)

8 (10)

12 (4)

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

14 (2.5)

Wire and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C (104°) ambient.

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.

Type SO cord or similar in 30°C ambient.

POWER WAVE® C300

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A-2

INSTALLATION

WIRE FEED SPEED RANGE-WIRE SIzE

WFS RANGE

GMAW

ALuMINuM

GMAW

MILD STEEL

GMAW

STAINLESS

WIRE SIzES

FCAW

WIRE SIzES WIRE SIzES

WIRE SIzES

50 – 700 ipm

(1.3 – 17.8 m/min)

.025 – .045"

(0.6 – 1.1mm) (0.8 – 1.2mm)

.030 – 3/64"

.035 – .045"

(0.9 – 1.1mm) (0.9 – 1.4mm)

.035 – .052"

WELDING PROCESS

OuTPuT RANGE (AMPERES)

OCV (uo)

PROCESS

GMAW

GMAW-Pulse

FCAW

40 - 300

40-70 VDC average, 100V peak

5 – 300

5 – 280

24 VDC average, 100V peak

60 VDC average, 100V peak

GTAW-DC

SMAW

WIRE SPEED RANGE

Wire Speed

50 – 700 IPM (1.27 – 17.8 m/minute)

PhYSICAL DIMENSIONS

MODEL

hEIGhT

18.8in (478mm)

WEIGhT

100.0lbs (47.6kg)*

DEPTh

WIDTh

27.4in (697mm)

K2675-2

14.00in (356mm)

TEMPERATuRE RANGES

STORAGE TEMPERATuRE RANGE

Environmentally Hardened: -40°F to 185°F (-40C to 85C)

OPERATING TEMPERATuRE RANGE

Environmentally Hardened: -4°F to 104°F (-20C to 40C)

IP23

155º(F) Insulation Class

* Weight does not include input cord.

Thermal tests have been performed at ambient tem-

perature. The duty cycle (duty factor) at 40°C has

been determined by simulation.

POWER WAVE® C300

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A-3

INSTALLATION

LIftING

SAfEtY PREcAUtIONS Read this

entire installation section before you start installa-

Both handles should be used when lifting POWER WAVE®

C300. When using a crane or overhead device a lifting strap

should be connected to both handles. Do not attempt to lift

the POWER WAVE® C300 with accessories attached to it.

tion.

WARNING

ELECTRIC ShOCK can kill.

Do not weld with the POWER WAVE® C300 while the

machine is suspended by the handles.

• Only qualified personnel should

perform this installation.

WARNING

• turn the input power Off at the

• Lift only with equipment of adequate

lifting capacity.

disconnect switch or fuse box before working on

this equipment. turn off the input power to any

other equipment connected to the welding system

at the disconnect switch or fuse box before work-

ing on the equipment.

• be sure machine is stable when lifting.

• Do not operate machine while suspend-

ed when lifting.

FALLING

• Do not touch electrically hot parts.

EQuIPMENT can

cause injury.

• Always connect the POWER WAVE® C300

grounding lug (located inside the reconnect

input access door) to a proper safety (Earth)

ground.

-----------------------------------------------------------------------------------------------

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.

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.

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.

• 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.

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.

• 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.

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).

• 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.

Locate the POWER WAVE® C300 away from radio con-

trolled machinery. The normal operation of the POWER

WAVE® C300 may adversely affect the operation of RF

controlled equipment, which may result in bodily injury or

damage to the equipment.

POWER WAVE® C300

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A-4

INSTALLATION

INPuT CONNECTION

WARNING

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

WARNING

Only a qualified electrician should

connect the input leads to the

POWER WAVE® C300. Connections

should be made in accordance with

all local and national electrical

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.

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.

------------------------------------------------------------------------

POWER CORD REPLACEMENT

------------------------------------------------------------------------

A 15 ft. power cord is provided and wired into the

machine. Follow the power cord connection instruc-

tions.

WARNING

Only a qualified electrician should

connect the input leads to the

POWER WAVE® C300. Connections

should be made in accordance with

all local and national electrical

codes and the connection diagram

located on the inside of the reconnect access

door of the machine. Failure to do so may result

in bodily injury or death.

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.

------------------------------------------------------------------------

If the input power cord is damaged or needs to be

Connect black, red and white leads to power.

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.

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 currents, even

if the machine is not being used at high currents.

FIGuRE A.1

NEL

BLACK

RED

WHITE

GREEEN

INPuT VOLTAGE SELECTION

INPUT CORD

GROUND LUG

ACCESS PANEL

The POWER WAVE® C300 automatically adjusts to

work with different input voltages. No reconnect

switches settings are required.

POWER WAVE® C300

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A-5

INSTALLATION

RECOMMENDED WORK CAbLE

SIzES FOR ARC WELDING

SEMI-AuTOMATIC WELDING

POLARITY

A 15 ft. work cable is provided with the POWER

WAVE® C300. This cable is appropriately sized for all

of the POWER WAVE® 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.

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.

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.

POWER WAVE® C300

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A-6

INSTALLATION

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)

TAbLE A.1

Function

Wiring

FIGuRE A.2

Supply Voltage for Dual Procedure

Dual Procedure Input

Trigger Input

4-pin trigger con-

nector for push-

only guns.

Supply Voltage for Trigger

CANL

CANH

Remote Pot Common

Remote Pot Wiper

Remote Pot +10VDC

ArcLink Peripheral Sense

Trigger

12 pin connector

for Push pull

guns; foot pedal;

remote controls;

Hand –amptrols.

Trigger

Power Common

Power +

Motor Negative

Motor Positive

CAbLE INDuCTANCE AND ITS

EFFECTS ON WELDING

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 length as

short as possible.

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).

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

WORK

POWER WAVE® C300

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A-7

INSTALLATION

ShIELDING GAS CONNECTION

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.

WARNING

CYLINDER may explode if

damaged.

6. Before opening the cylinder valve, turn the regulator

adjusting knob counterclockwise until the adjusting

spring pressure is released.

• 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.

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.

8. The flow regulator is adjustable. Adjust it to the flow

rate recommended for the procedure and process

being used before making a weld

• 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:

1. 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. Remove 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.

4. 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.

POWER WAVE® C300

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A-8

INSTALLATION

LOADING SPOOLS OF WIRE

WARNING

• Keep hands, hair, clothing and tools away from

rotating equipment.

• Do not wear gloves when threading

wire or changing wire spool.

• Only qualified personnel should install,

use or service this equipment.

------------------------------------------------------------------------

Loading 10 to 15 lb. (4.5 – 6.8kg) Spools.

A K468 spindle adapter 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 lb. (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 the groove on the spindle

POWER WAVE® C300

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A-9

INSTALLATION

WIRE DRIVE CONFIGuRATION

(See Figure A.4)

Changing the Gun Receiver bushing

8. 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.

WARNING

ELECTRIC ShOCK can kill.

• Turn the input power OFF at the

welding power source before instal-

lation or changing drive rolls and/or

guides.

11. Insert the welding gun into the gun bushing and

tighten the thumb screw.

PROCEDuRE TO INSTALL DRIVE

ROLLS AND WIRE 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.

• Do 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.

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.

• Do not operate with covers, panels or guards

removed or open.

• Only qualified personnel should perform mainte-

nance work.

------------------------------------------------------------------------

1. Turn power off at the welding power source.

2. Release the idle roll pressure arm.

3. Remove the outer wire guide by turning the knurled

thumbscrews counter-clockwise to unscrew them

from the feed plate.

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.

4. Rotate the triangular lock and remove the drive

rolls.

7. Disconnect the shielding gas hose from the gun

bushing, if required.

FIGuRE A.5

THUMB SCREW

GUN RECEIVER BUSHING

OUTER WIRE GUIDE

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 triangular lock.

8. Install the outer wire guide by aligning it with the

pins and tightening the knurled thumbscrews.

9. Close the idle arm and engage the idle roll pressure

arm. Adjust the pressure appropriately

CONNECTOR BLOCK

SOCKET HEAD

CAP SCREW

LOOSEN

TIGHTEN

POWER WAVE® C300

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A-10

INSTALLATION

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.

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.

2. If 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.

FEEDING ELECTRODE AND bRAKE

ADJuSTMENT

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.

1. Turn the Reel or spool until the free end of the

electrode is accessible.

2. While tightly holding the electrode, cut off the bent

end and straighten the first 6" (150 mm). Cut off

the first 1" (25 mm). (If the electrode is not properly

straightened, it may not feed or may jam causing a

"birdnest".)

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 performance.

3. Insert the free end through the incoming guide

tube.

4. Press the Cold Inch key and push the electrode

into the drive roll.

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

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.

FIGuRE A.6

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.

ALUMINUM

Aluminum wires

FLUX CORE

ARC WELDING

Cored wires

GAS METAL

ARC WELDING

Steel, Stainless wires

• Do not touch electrically live parts.

• When feeding with the gun trigger, unless

“COLD FEED” trigger mode is 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:

POWER WAVE® C300

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A-11

INSTALLATION

TIG WELDING

(Figure A.7)

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.

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.

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

)

ROL

)

12 PIN CONNECTOR

GAS SUPPLY

CONNECTION

4 PIN GUN TRIGGER

CONNECTOR

NEGATIVE

STUD (-)

POSITIVE

STUD (+)

TO POSITIVE

STUD (+)

WORK CLAMP

WORK PIECE

TO NEGATIVE

STUD (-)

POWER CABLE

TO GAS SUPPLY

CONNECTION

GAS HOSE

TIG TORCH

TO REMOTE CONTROL

RECEPTACLE

FOOT AMPTROL

(OPTIONAL)

POWER WAVE® C300

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b-1

OPERATION

GRAPhIC SYMbOLS ThAT APPEAR ON

ThIS MAChINE OR IN ThIS MANuAL

SAFETY PRECAuTIONS

READ AND uNDERSTAND ENTIRE SECTION

bEFORE OPERATING MAChINE.

WARNING OR

CAuTION

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.

• Do not operate with covers, panels or guards

removed or open.

---------------------------------------------------------------------

• FuMES AND GASSES can be

dangerous.

DANGEROuS

VOLTAGE

POSITIVE OuTPuT

NEGATIVE OuTPuT

hIGh TEMPERATuRE

• Keep your head out of fumes.

• use ventilation or exhaust to

remove fumes from breathing

zone.

STATuS

---------------------------------------------------------------------

• WELDING SPARKS can cause

fire or explosion.

PROTECTIVE

GROuND

• Keep flammable material away.

POWER-uP SEQuENCE

---------------------------------------------------------------------

ARCꢀRAYS can burn.

• Wear eye, ear and body protec-

tion.

When the POWER 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.

---------------------------------------------------------------------

SEE ADDITIONAL WARNING INFORMATION

uNDER ARC WELDING SAFETY PRECAuTIONS

AND IN ThE FRONT OF ThIS OPERATING MAN-

uAL.

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

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b-2

OPERATION

PROCESS LIMITATIONS

PRODuCT DESCRIPTION

The software based weld tables of the Power Wave® 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 and 3/64 Aluminum wire.

1/16 Aluminum wire is not supported.

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 following items will not be supported on this product,

but may be supported by other product in the product portfo-

lio:

The Power Wave® C300 will provide the following:

• Power - 300A @ 40%, 275A @ 60%, 250A @

100%.

• STT

• Multi Input Voltage with no reconnect - 200-600V,

50-60 Hz input.

• Single and Three Phase Power.

• < 95% Power factor – optimizes available electrical

capacity / especially useful when limited to inputs of

230VAC – 1 phase.

• AC welding processes

WARNING

The Power Wave® C300 is not recommended for pipe

thawing.

---------------------------------------------------------------------

• Environmentally Hardened - IP23 rated for operating

in difficult environments.

• Versatile Feeding Options – Standard Mig guns,

Spool guns, and Push-pull guns.

EQuIPMENT LIMITATIONS

• Ethernet connectivity – allows access to the Power

Wave utilities software tools.

• Maximum gun length is 25 ft (7.6m) for push-only

systems.

• Maximum gun length is 50 ft (15.2) for push-pull

systems.

RECOMMENDED PROCESSES AND

• Maximum spool size is 12 in (305 mm) diameter.

• Maximum spool weight is 44 lb (20 kg).

• Other gun bushings are required for welding guns

that do not have a Magnum (Tweco #2-#4 compati-

ble) back end.

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.

POWER WAVE® C300

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b-3

OPERATION

• Patent pending dual spring pressure arms have

sensitivity for feeding soft wires without crushing

them, and have plenty of compression force for

feeding solid or stiff wires.

• All gear driven rolls for more feeding force.

• Changeable gun bushings easily accept guns from

other manufacturers.

• Brass-to-brass connections between the electrode

connection and the gun minimize voltage drop vari-

ations, resulting in consistent arc performance all

day, every day.

• Powerful, quiet motor with integrated tachometer for

accurate WFS regulation.

DESIGN FEATuRES

Loaded with Standard Features

• Multiple process DC output range: 5 - 300 Amps.

• 200 – 600 VAC, 1/3 phase, 50-60Hz input power.

• New and Improved Line Voltage Compensation

holds the output constant over wide input voltage

fluctuations.

• Utilizes next generation microprocessor control,

based on the ArcLink® platform.

• State of the art power electronics technology, yields

superior welding capability.

• Electronic over current protection.

• Input over voltage protection.

• 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 ruggedness/reliabili-

ty.

• 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.

• No tools required to change the drive rolls and wire

guides.

POWER WAVE® C300

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b-4

OPERATION

CASE FRONT CONTROLS

FIGuRE b.1

All operator controls and adjustments are located on

the case front of the Power Wave. (See Figure b.1)

9. ON/OFF SWITCh- Controls power to the Power

Wave® C300.

1. LEFT DISPLAY- Shows wire feed speed or amper-

age,

10. RIGhT DISPLAY- Shows voltage or trim.

11. ThERMAL LIGhT- Indicates when machine has

thermal fault.

12. RIGhT KNOb- Adjusts value in right display.

2. LEFT KNOb- Adjusts value in left display.

3. MAIN DISPLAY- Shows detailed welding and diag-

nostic information.

13. SET-uP- Lights when machine is in set-up mode,

4. LEFT buTTON- Changes the Main display to

show the Weld Mode or Arc Control.

14. RIGhT buTTON- Used to toggle start options

and to end options.

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.

POWER WAVE® C300

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b-5

OPERATION

CASE bACK CONTROLS

FIGuRE b.2

1. EThERNET CONNECTOR

2. POWER CORD

3. GAS CONNECTION, GMAW AND FCAW

4. Gas Connection, GTAW

POWER WAVE® C300

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b-6

OPERATION

INTERNAL CONTROLS

(Code 11479)

FIGuRE b.3

7. 12 PIN CONNECTOR

1. SPINDLE bRAKE

2. WIRE DRIVE PRESSuRE ARM

8. NEGATIVE STuD

9. POSITIVE STuD

3. ThuMb SCREW, FOR SECuRING ThE WELDING GuN

10. 4 PIN TRIGGER RECEPTACLE

11. COLD INCh / GAS PuRGE SWITCh

12. GAS CONNECTION, GTAW

4. GuN buShING

5. SOCKET hEAD CAP SCREW FOR SECuRING

ThE GuN buShING

6. GAS CONNECTION, GMAW OR FCAW GuN

POWER WAVE® C300

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b-7

OPERATION

bASIC WELDING CONTROLS

MAKING A WELD WITh WAVEFORM

TEChNOLOGY POWER SOuRCES

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.

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.

WIRE FEED SPEED (WFS)

In synergic welding modes (synergic CV, GMAW-P),

WFS is the dominant control parameter. The 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.

---------------------------------------------------------------------

Choose the electrode material, electrode size, shield-

ing gas, and process (GMAW, GMAW-P etc.) appro-

priate for the material to be welded.

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.

Select the weld mode that 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.

AMPS

In constant current modes, this control adjusts the

welding current.

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)

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.

DEFINITION OF WELDING MODES

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding

process variables to be set by the operator.

uLTIMARC^TMCONTROL

UltimArc^TMControl allows the operator to vary the arc

characteristics

from

“soft”

“crisp”.

SYNERGIC WELDING MODES

UltimArc™Control is adjustable from –10.0 to +10.0

with a nominal setting of 0.0.

• A 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.

POWER WAVE® C300

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b-8

OPERATION

CASE FRONT CONTROLS uSED

rc™

AMPS

TRIM

WIRE FEED SPEED (WFS)

AMPS

VOLTS

TRIM

OUTPUT

AMPS

OUTPUT

OFF

LESS

AMPS

SETUP

WELD MODE

START OPTIONS

END OPTIONS

UltimArc™ Control

DuAL PROCEDuRE/

MEMORY PANEL OPERA-

TION

POWER WAVE® C300

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b-9

OPERATION

SMAW (STICK) WELDING

SMAW is most often used for outdoor construction,

pipe welding and general repairs. The wire feeder

controls Amperage, Output Control and Arc Force dur-

ing SMAW welding.

During SMAW welding the wire drive remains idle.

bASIC OPERATION

WFS

VOLTS

TRIM

0 _n

194

AMPS

OUTPUT

AMPS

OUTPUT

OFF

LESS

AMPS

CONTROL OPTIONS

CC STICK MODES

START OPTIONS

No arc starting options are active for

(Stick) welding modes.

PROCESS

MODE

SMAW

Stick Soft(7018)

Stick Crisp(6010)

SETUP

Stick Crisp

WELD MODE

START OPTIONS

END OPTIONS

UltimArc™ Control

END OPTIONS

No arc ending options are active for

(Stick) welding modes.

UltimArc™ Control

EFFECT / RANGE

DESCRIPTION

SMAW

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

ARC FORCE

(Soft)-10.0 to

(Crisp)+10.0

par

electrodes,

of organic coated

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.

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.

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b-10

OPERATION

NON-SYNERGIC GMAW AND FCAW

WELDING

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).

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 compensate for any changes made to

the WFS.

bASIC OPERATION

ing.

MODE 40

MODES 5 AND 6

WFS

VOLTS

TRIM

VOLTS

TRIM

250

300

25.3

AMPS

VOLTS

WFS

LESS

WFS

VOLTS

WFS

LESS

WFS

VOLTS

START OPTIONS

DESCRIPTION

CONTROL OPTIONS

EFFECT

Preflow Time

A d j u s t s t h e time

shieldinggas

that

pulled

after the trigger is

prior to feeding wire.

flows

and

Run-In WFS:

Run-In sets the wire feed

speed from the time the trigger

is pulled until an arc is estab-

lished.

Start Procedure

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 the preset Welding

Procedure.

WELD MODE

PROCESS

WELD MODE

GMAW, STANDARD CV

GMAW, POWER MODE

FCAW, STANDARD CV

SETUP

STD CV MIG

WELD MODE

START OPTIONS

END OPTIONS

UltimArc™ Control

END OPTIONS

DESCRIPTION

EFFECT

Spot Timer

UltimArc™ Control

Adjust the time welding will

continue even if the trigger

is still pulled. This option

has no effect in 4-Step

Trigger Mode.

EFFECT / RANGE

DESCRIPTION

PINCH

Pinch controls the arc characte-

-ristics when short-arc welding.

(Soft)-10.0 to

(Crisp)+10.0

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.

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:

Postflow Time

Adjusts the time that shielding

gas flows after the welding out-

put turns off.

POWER WAVE® C300

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b-11

OPERATION

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.

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 voltage level corre-

spondingly to maintain similar arc characteristics

throughout the WFS range.

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)

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).

• Preset voltage at ideal

voltage. (no bar displayed)

• Preset voltage below ideal

voltage. (lower bar displayed)

bASIC OPERATION

WFS

VOLTS

TRIM

220

26.4

AMPS

Less

Longer

Arc

Shorter

Arc

Deposition

START OPTIONS

CONTROL OPTIONS

EFFECT

DESCRIPTION

Preflow Time

Adjusts thetime t h a t s h i e l d i n g

gas

flows after thetrigger 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-

lished.

WELD MODE

Run-in WFS:

WIRE SIZE

ELECTRODE AND GAS

0.030 0.035 0.045 0.052

Steel

CO₂

---

Ar(Mix)

Ar/He/CO₂

Start Procedure

The Start Procedure controls

the WFS, Volts 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.

Stainless

Aluminum 4043

Aluminum 5356

148

151

SETUP

STEEL

.035"

CO2

START OPTIONS

END OPTIONS

WELD MODE

UltimArc™ Control

END OPTIONS

UltimArc™ Control

DESCRIPTION

Pinch controls the arc characte-

-ristics when short-arc welding.

EFFECT

Spot Timer

DESCRIPTION

EFFECT / RANGE

PINCH EFFECT

(-10.0 to +10.0)

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.

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:

Postflow Time

Adjusts the time that shielding

gas flows after the welding out-

put turns off.

POWER WAVE® C300

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b-12

OPERATION

STEEL AND STAINLESS SYNERGIC GMAW-P (PuLSED MIG) WELDING

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.

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 “trim” is used for

adjusting 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

Trim 1.50

Trim 1.00

Trim .50

Arc L ength Long

Arc Length Medium

Arc Length Short

uLTIMARC™ CONTROL

(See Figure b.6)

UltimArc™ Control adjusts the focus or shape of the arc.

UltimArc™ Control is adjustable from -10.0 to +10.0 with

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.

nominal setting of 0.0. Increasing the

UltimArc™Control increases the pulse frequency and

background current while decreasing the peak current.

FIGuRE b.6

eq cy

UltimArc™ Control +10.0

Hi gh Frequency, Fo cu sed

UltimArc™ Control OFF

UltimArc™ Control -10.0

Low Frequency, Wi de

Med ium Fr equency and Wi dth

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.

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.

POWER WAVE® C300

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b-13

OPERATION

STEEL AND STAINLESS GMAW-P

(PuLSED MIG) WELDING

bASIC OPERATION

WFS

VOLTS

TRIM

1.06

220

AMPS

Longer

Arc

Shorter

Arc

Less

Deposition

START OPTIONS

DESCRIPTION

CONTROL OPTIONS

EFFECT

Postflow Time

Adjusts the time that shielding

gas

flows after the trigger

WELD MODE

GAS

prior to feeding wire.

and

pulled

WIRE SIZE

0.030 0.035 0.045 0.052

RUN-IN WFS:

ELECTRODE AND

Run-in sets the wire feed

speed from the time the trigger

is pulled until an arc is estab-

lished.

Steel(Crisp)

201

---

Ar(Mix)

Ar/ CO₂

Ar/He/CO₂

---

Steel(Soft)

Stainless

---

Start Procedure

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.

---

Stainless

---

SETUP

STEEL

Pulse

.035"

Crisp ArMix

START OPTIONS

END OPTIONS

WELD MODE

UltimArc™ Control

END OPTIONS

FUNCTION

EFFECT

Spot Timer

UltimArc™ Control

EFFECT / RANGE

DESCRIPTION

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.

Arc Focus adjusts the arc from

a wide, soft arc good for out of

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.

ARC FOCUS

-10.0 (SOFT to

10.0 (STIFF)

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:

Postflow Time

Adjusts the time that shielding

gas flows after the welding out-

put turns off.

POWER WAVE® C300

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b-14

OPERATION

ALuMINuM SYNERGIC GMAW-P

(PuLSED MIG)AND GMAW-PP

(PuLSE ON PuLSE) WELDING

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.

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

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.

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

(See Figure B.10)

FIGuRE b.10

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)

Trim 1.50

Arc L ength Long

Trim 1.00

Arc Length Medium

Trim .50

Arc Length Short

FIGuRE b.8

Modulation Frequency = -10

Wide weld and ripple spacing, slow travel speed.

FIGuRE b.9

Modulation Frequency = 10

Narrow weld and ripple spacing, fast travel speed.

POWER WAVE® C300

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b-15

OPERATION

ALuMINuM GMAW-P (PuLSED MIG)

AND GMAW-PP (PuLSE ON PuLSE)

WELDING

bASIC OPERATION

WFS

VOLTS

TRIM

220

1.06

AMPS

Longer

Arc

Shorter

Arc

Less

Deposition

CONTROL OPTIONS

START OPTIONS

DESCRIPTION

EFFECT

Postflow Time

Adjusts the time that shielding

gas

flows

the trigger is

after

pulled

prior to feeding wire.

and

RUN-IN WFS:

WELD MODES

Run-in sets the wire feed

speed from the time the trigger

is pulled until an arc is estab-

lished.

WIRE SIZE

0.035 3/64 1/16

149 72 74

98 99 100

152 76 78

101 102 103

ELECTRODE AND GAS

ALUMINUM 4043

ALUMINUM 5356

Start Procedure

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.

SETUP

Aluminum

3/64"

4043 Ar

Pulse

START OPTIONS

END OPTIONS

WELD MODE

UltimArc™ Control

END OPTIONS

FUNCTION

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.

EFFECT

UltimArc™ Control

Spot Timer

EFFECT / RANGE

DESCRIPTION

PULSE

For Pulse

modes, Arc Control

FREQUENCY:

changes the pulsing frequency.

When the frequency changes,

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,

Arc controls changes the frequ-

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

Crater Procedure

PULSE-ON-PULSE

FREQ.MODULATION

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:

(Low)-10.0 to

(High)+10.0

Postflow Time

Adjusts the time that shielding

gas flows after the welding out-

put turns off.

POWER WAVE® C300

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b-16

OPERATION

GTAW (TIG) WELDING

The Power Wave® C300 is excellent for Touch Start

TIG welding.

bASIC OPERATION

Maximum

Amperage

WFS

VOLTS

TRIM

220

OFF

AMPS

OUTPUT

OFF

OUTPUT

CONTROL OPTIONS

WELD MODE

MODE

TOUCH START

START OPTIONS

No Arc starting Options are

active for Touch Start TIG

SETUP

TOUCH START TIG

START OPTIONS

END OPTIONS

WELD MODE

UltimArc™ Control

END OPTIONS

DESCRIPTION

EFFECT

Crater Time

UltimArc™ Control

No UltimArc™ Control are

active for Touch Start TIG.

Function

During the Crater time, the

machine will ramp up or down

from the Weld Procedure to

the Crater Procedure.

0 To 10 seconds

WELD MODE SEARChING

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.

The Weld Mode Search feature allows the selection of

a welding mode based on certain criteria (wire size,

process type, etc.).

Rotate the control knob then press the right pushbut-

ton to select relevant welding details such as welding

process, wire type, wire size, etc.

SEARChING FOR A WELD MODE

To search for a mode, turn the control knob until

“Weld Mode Search” is displayed. This will appear in

between the highest and the lowest weld mode num-

bers.

When the final selection is made, the C300

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

Once “Weld Mode Search” is displayed, pressing the

right pushbutton labeled “Begin” will start the search

process.

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OPERATION

DuAL PROCEDuRE/MEMORY PANEL

uSER MEMORIES

OPERATION

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.

The Dual Procedure/Memory Panel performs three

functions:

• Weld procedure selection

• Memory save and recall

• Limits setting

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 disabled. Use

the SETUP menu and change P.4 to enable memory

recall with the gun trigger.

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

the selected procedure memory.

Save a memory with memory buttons

USER

MEMORIES

ARE COPIED TO

PROCEDURE

MEMORY

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.

(8) USER

MEMORIES

PROCEDURE

MEMORY

GUN

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

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.

GUN

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

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.

GUN

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OPERATION

LIMITS

Set Limits:

Press 5

seconds

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-

ry 3 may not have any WFS limits.

GUN

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.

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.

The system machine limits are:

Range

Weld mode and wire

feeder dependent.

Parameter

Wire Feed Speed

units

in/min

SETUP

Weld mode dependent

0.50 to 1.50

-10.0 to 10.0

0.0 to 2.5

Voltage

Trim

Volts

Memory 2

Set Limits

START OPTIONS

END OPTIONS

WELD MODE

UltimArc™ Control

UltimArc™Control

Preflow

Weld mode dependent

Seconds

0.0 to 10.0

Start Time

Seconds

Off, 50 to 150

0.0 to 10.0

Run-In WFS

Crater Time

Burnback Time

Postflow Time

in/min

Seconds

0.00 to 0.25

0.0 to 10.0

Seconds

Limits may be set for:

• Wire Feed Speed/Amperage

• Voltage/Trim

• UltimArc™Control

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.

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OPERATION

The memory value must always be less than or equal

to the high limit, and greater than or equal to the low

limit.

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.

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) to exit and leave

limits unchanged.

Memory Value

Low Limit

high Limit

200

SETUP

HI = 200

LO = 180

Enabling/Disabling Limits

WELD WFS

START OPTIONS

END OPTIONS

WELD MODE

Enable/Disable

Limits: Press

10 seconds

UltimArc™ Control

Parameter Name

GUN

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

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:

• 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.

SETUP

MEMORY 2 LIMITS

200

ENABLE / DISABLE

SETUP

HI = 200

LO = 180

START OPTIONS

WELD MODE

WELD WFS

UltimArc™ Control

END OPTIONS

START OPTIONS

END OPTIONS

WELD MODE

UltimArc™ Control

If the passcode does not equal zero, enter the passcode

now. If the passcode is zero (0000), SETUP will light

and the MSP4 displays the following:

Rotate to

Change

Value.

Press to

select item

to change.

SETUP

ENABLE LIMITS?

Yes

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.

START OPTIONS

END OPTIONS

WELD MODE

UltimArc™ Control

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.

To lock a parameter to a specific value that can-

not be changed, set the high and low limits to the

same value.

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OPERATION

2-STEP 4-STEP-

OPERATION

TRIGGER

The 2-Step - 4-Step switch changes the function of

the gun trigger. 2-Step trigger operation switches the

welding output ON-OFF in direct response to the 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 4-Step operation.

The 2-Step, 4-Step trigger has no effect when weld-

ing with SMAW.

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.

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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 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

Burnback = OFF

Idle

Preflow

Weld

Postflow

Idle

Run-In

Off

Shielding

Gas

Weld

Power

Source

Output

1.5 sec max.

Off

Weld

WFS

Run- in

Off

POWER WAVE® C300

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OPERATION

ExAMPLE 2 - 2 STEP TRIGGER: Improved Arc Start

and Arc End. Tailoring the arc start and arc end is a

common method for reducing spatter and improving

weld quality. This can be accomplished with the Start

and Burnback functions set to a desired values and

Crater set to OFF. (See Figure B.12)

uPSLOPE:

Once the wire touches the work and an arc is 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.

For this sequence,

PREFLOW:

Shielding gas begins to flow immediately when the

gun trigger is pulled.

WELD:

After upslope, the power source output and the wire

feed speed continue at the weld settings.

buRNbACK:

RuN-IN:

As soon as the trigger is released, the wire feed

speed is turned OFF and the machine output contin-

ues for the burnback time.

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.

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

Crater = OFF

Burnback = ON

Idle

Preflow

Upslope

Weld

Burnback

Postflow

Idle

Run-In

Off

Shieldin

Gas

Start

time

Weld

Power

Source

Output

1.5 sec max.

Burnback Time

Start

Off

Weld

WFS

Run-in

Off

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OPERATION

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)

WELD:

After upslope, the power source output and the wire

feed speed continue at the weld settings.

CRATER & 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.

For this sequence,

PREFLOW:

Shielding gas begins to flow immediately when the

gun trigger is pulled.

buRNbACK:

After the crater time expires, the wire feed speed is

turned OFF and the machine output continues for the

burnback time.

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.

POSTFLOW:

Next, the machine output is turned OFF and shielding

gas continues until the post flow timer expires.

START & uPSLOPE:

As soon as the trigger is 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.

FIGuRE b.13

2 Step Trigger

Start = ON

Crater= ON

Burnback = ON

Idle

Preflow

Strike

Upslope

Weld

Downslop e Burnback

Postflow

Idle

Off

Shielding

Gas

Start t ime

Crater ti me

Weld

1.5 secmax.

Burnback Time

Power

Source

Output

Start

Crater

Off

Weld

WFS

Crater

Run-in

Off

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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

Idle

Preflow Strike

Wel

Burnback Postflow

Idle

Off

Shielding

Gas

We ld

1. 5s ec max.

Power

Source

Output

Start

Crater

Off

We ld

WFS

Crate r

Run-in

Off

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OPERATION

uPSLOPE:

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)

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.

In this sequence,

PREFLOW:

Shielding gas begins to flow immediately when the

gun trigger is pulled.

CRATER:

During CRATER, the power source continues to sup-

ply output at the crater WFS and voltage.

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.

buRNbACK:

When the trigger is released, the wire feed speed is

turned OFF and the machine output continues for the

burnback time.

START:

The power source welds at the start WFS and voltage

until the trigger is released.

POSTFLOW:

Next, the machine output is turned OFF and shielding

gas continues until the post flow timer expires.

FIGuRE b.15

4 Step Trigger

Start = ON

Crater= ON

Burnback = ON

Idl e

Preflow Strike

Start

Upslope

Weld

Downslope

Crater

Burnback Postflo w

Idle

Off

Shielding

Gas

Wel d

Start

1.5 sec max.

BurnbackTime

Po wer

So urce

Out put Crater

Off

Wel d

St art

Crater

Stri ke

WFS

Off

POWER WAVE® C300

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OPERATION

3. Operation with POWER WAVE® C300:

COLD FEED/GAS PuRGE SWITCh

•

Install the spool gun per the installation instructions

COLD FEED

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).

Cold Feed and Gas Purge are com-

bined into a single spring centered tog-

gle switch.

•

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.

GAS PURGE

To activate Cold Feeding, hold the

switch in the FORWARD position. The

wire drive will feed electrode but neither the power

source nor the gas solenoid will be energized. Adjust

the speed of cold feeding by rotating the WFS knob.

Cold feeding, or "cold inching" the electrode is useful

for threading the electrode through the gun.

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.

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.

•

The left Display (WFS / AMPS) on the Power

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.

SPOOL GuN OPERATION

•

The following procedure settings for Aluminum

4043 can be used as initial settings for making

test welds to determine final settings:

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.

Wire Dia.

In. (mm)

WFS Setting

Spool Gun

Arc Voltage

Setting

.030" (.8 mm)

.035" (.9 mm)

3/64" (1.2 mm)

270

250

240

15V

16V

20V

CAuTION

4. Synergic Weld Modes

Closing either gun trigger will cause the electrode of

both guns to be electrically “hOT”. be sure unused

gun is positioned so electrode or tip will not contact

metal case or other metal common to work.

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).

---------------------------------------------------------------------------

Because the control circuitry senses each gun through its

trigger leads, weld parameters are displayed and

adjustable for the last gun that was triggered.

•

In 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.

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.

•

The left control knob adjusts the SPD value.

The right control knob is inactive.

•

Closing feeder gun trigger starts feeder gun weld-

ing and makes both electrodes electrically “HOT”.

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.

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”.

POWER WAVE® C300

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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 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 than the actual WFS.

Remember; do not change the WFS at the spool

gun.

• To 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

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OPERATION

SETuP MENu FEATuRES

The Setup Menu gives access to the Setup Configuration. Stored in the setup configuration are user parameters

that generally only need to be set at installation. The parameters are grouped as shown in the following table.

PARAMETER

P.1 through P.99

P.101 through P.199

P.501 through P.599

DEFINITION

Unsecured Parameters (always adjustable)

Diagnostic Parameters (always read only)

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

User

Exit

Prefs

Left

Right

button

SET Knob

POWER WAVE® C300

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OPERATION

uSER DEFINED PARAMETERS

Parameter

P.0

Definition

Exit Setup Menu

This option is used to exit the setup menu. When P.0 is displayed, press the Left Button to exit

the setup menu.

P.1

P.2

P.3

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.

P.4

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, quickly 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.

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b-30

OPERATION

uSER DEFINED PARAMETERS

Parameter

P.5

Definition

Procedure Change Method

Selects how remote procedure selection (A/B) will be made. The selected procedure can be

changed locally at the user interface by pressing the 'A-Gun-B' button. The following methods

can be used to remotely change the selected procedure:

• Use an external switch wired to the procedure select input.

• Quickly releasing and re-pulling the gun trigger.

• 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:

1. Select "GUN" on the memory panel.

2. Start the weld by pulling the gun trigger. The system will weld with procedure A settings.

3. 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.

4. 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).

P.6

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 tip

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.

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OPERATION

uSER DEFINED PARAMETERS

Parameter

P.7

Definition

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:

1. Release the pressure arm on both the pull and push wire drives.

2. Set the wire feed speed to 200 ipm.

3. Remove wire from the pull wire drive.

4. Hold an rpm meter to the drive roll in the pull gun.

5. Pull the trigger on the push-pull gun.

6. 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.

P.8

TIG Gas Control

This option allows control over which gas solenoid actuates while TIG welding.

"Valve (manual)" = 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

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 Amptrol, 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.

P.9

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).

P.14

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.

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b-32

OPERATION

uSER DEFINED PARAMETERS

Parameter

P.16

Definition

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

speed. 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.

P.17

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 (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)

P.20

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.

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b-33

OPERATION

uSER DEFINED PARAMETERS

Parameter

P.22

Definition

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.

P.80

P.81

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 sense leads. This

option will only appear in the list if the power source has a hardware selection option. 67 pos

polarity = 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 & 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.

P.82

P.99

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.

P.100

View Diagnostic?

Diagnostics are only used for servicing or troubleshooting the Power Wave system. Select

"Yes" to access the diagnostic options in the menu. Additional parameters will now appear in

the setup menu (P.101, P.102, etc).

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b-34

OPERATION

uSER DEFINED PARAMETERS

Parameter

P.102

Definition

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.

P.103

P.104

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.

P.105

P.106

P.107

P.501

View Welding Software Information

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

P.502

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.

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b-35

OPERATION

uSER DEFINED PARAMETERS

Parameter

P.503

Definition

Memory button Disable

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.

P.504

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.

• 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 = The 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.

P.505

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.

P.506

P.509

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.

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b-36

OPERATION

uSER DEFINED PARAMETERS

Parameter

P.507

Definition

uI Clear All Memories

Allows the operator to quickly set all memories to the default weld mode and welding parame-

ters. Presently, this option does not exist in any setup menu.

P.509

uI Master Lockout

Locks all user interface controls, preventing the operator from making any changes. This para-

meter can only be accessed using Power Wave Manager.

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C-1

ACCESSORIES

OPTIONS / ACCESSORIES

K870 FOOT AMPTROL

Requires K2909-1, 6-pin to 12-pin

adapter.

STICK OPTIONS

K875 ACCESSORY KIT - 150 Amp

K870-2 FOOT AMPTROL

(12-pin plug connection)

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.

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.

K857, K857-1 REMOTE OuTPuT

CONTROL

Requires K2909-1, 6-pin to 12-pin

adapter.

Provides 25 ft (7.6m) of remote cur-

rent control for TIG welding. (6-pin

plug connection).

K963-4 hAND AMPTROL

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.

Provides 25 ft (7.6m) of remote current control for TIG

welding. (12-pin plug connection).

TIG OPTIONS

PTA-17

Premium Air-Cooled Models

K1782-2

PTA-17 TIG Torch (12.5 ft 3.8m)

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

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C-2

ACCESSORIES

WIRE FEEDER OPTIONS

K2447-1 PYThON-PLuS

PuSh-PuLL GuN Air-Cooled,

15 ft.(4.5m). Requires K2910-1, 7-pin

to 12-pin adapter.

K2447-2 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

100% 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.

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 Air-Cooled, 15

ft.(4.5m). Requires K2910-1, 7-pin to

12-pin adapter.

K2874-2 PANThER PuSh-

PuLL GuN Air-Cooled, 25

ft.(7.6m). Requires K2910-1, 7-pin 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.

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D-1

MAINTENANCE

SAFETY PRECAuTIONS

WARNING

ELECTRIC ShOCK can kill.

• Do not operate with covers

removed.

• Turn off power source before

installing or servicing.

• Do not touch electrically hot

parts.

• Turn the input power to the welding power

source off at the fuse box before working in the

terminal strip.

• Only qualified personnel should install, use or

service this equipment.

------------------------------------------------------------------------

ROuTINE MAINTENANCE

Routine maintenance consists of periodically blowing

out the machine, using a low-pressure air stream, to

remove accumulated dust and dirt from the intake and

outlet louvers, and the cooling channels in the

machine.

PERIODIC MAINTENANCE

Calibration of the Power Wave® 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 machine calibration will not need

adjustment. However, if the weld performance

changes, or the yearly calibration check reveals a

problem, use the calibration section of the

Diagnostics utility to make the appropriate 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.

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E-1

TROubLEShOOTING

hOW TO uSE TROubLEShOOTING GuIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.

Unauthorized repairs performed on this equipment may result in danger to the technician and

machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical

Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

This Troubleshooting Guide is provided to help you

locate and repair possible machine malfunctions.

Simply follow the three-step procedure listed below.

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.

Step 1. LOCATE PROBLEMꢀ(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.

If you do not understand or are unable to perform the

Recommended Course of Action safely, contact your

local Lincoln Authorized Field Service Facility.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists

the obvious external possibilities that may contribute

to the machine symptom.

WARNING

ELECTRIC ShOCK can kill.

• Turn the input power OFF at the welding power source before installation or changing

drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and

ground and could remain energized several seconds after the gun trigger is released.

• Welding power source must be connected to system ground per the National Electrical Code or any

applicable local codes.

• Only qualified personnel should perform maintenance work.

Observe all additional Safety Guidelines detailed throughout this manual.

CAuTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

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E-2

TROubLEShOOTING

There is an audible beeper associated with this input control

board’s status light. So the error codes on the input board

can be detected through either the status light or the status

beeper.

uSING ThE STATuS LED TO

TROubLEShOOT SYSTEM PRObLEMS

Not all of the Power Wave C300 errors will be displayed on

the user interface. There are three status lights that contain

error sequences that may not show up on the user interface.

If a problem occurs it is important to note the condition of

the status lights. Therefore, prior to cycling power to the 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

control board is one color. Normal operation is for the status

light to be off ( and the buzzer to be off).

There are two externally mounted status lights located

above the wire drive in the wire feeder compartment. One of

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 following Table E.1.

TAbLE E.1

Light

Condition

Meaning

Main control board status light and Wiredrive Status Light

Input control board

Steady Green

Blinking Green

SystemOK. Powersourceisoperational, andiscommunicatingnormallywithall

healthyperipheralequipmentconnectedtoitsArcLinknetwork.

Not applicable.

Occurs during power up or a system reset, and indicates the POWER

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.

Not applicable.

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-

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), turn power source off, and back on to

reset.

Steady Red

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.

Status LED off

Not applicable.

System OK

CAuTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

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E-3

TROubLEShOOTING

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)

Error Code #

Indication

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

58 Primary Fault 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 Service Department.

Review error code from input board status light or status beeper.

Most likely caused by an over power condition which caused an

under voltage on the primary bus. If cycling the input power on the

machine does not clear the error, contact the Service Department.

Other

Error codes that contain three or four digits are defined as fatal

errors. These codes generally indicate internal errors on the Power

Source Control Board. If cycling the input power on the machine

does not clear the error, contact the Service Department.

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

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E-4

TROubLEShOOTING

Observe all Safety Guidelines detailed throughout this manual

INPUt cONtROL BOARD

Error Code #

Indication

331 Peak input current limit

Input current limit has been exceeded. Typically indicates short

term power overload. If problem persists contact Service

Department.

333 Under-voltage lockout

+15 VDC supply on Input control board too low. Verify input voltage

is within the acceptable range. If problem persists contact service

department.

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.

Other

Contact the Service Department.

CAuTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER WAVE® C300

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E-5

TROubLEShOOTING

Observe all Safety Guidelines detailed throughout this manual

PRObLEMS

(SYMPTOMS)

POSSIbLE

CAuSE

RECOMMENDED

COuRSE OF ACTION

basic Machine Problems

1. Make sure fuses are properly

sized. See installation section of

this manual for recommended

sizes.

Input fuses keep blowing

1. Improperly sized input fuses.

2. Reduce output current, duty

cycle, or both.

2. Improper Weld Procedure requir-

ing output levels in excess of

machine rating.

3. Contact your local authorized

Lincoln Electric Field Service

facility for technical assistance.

3. Major physical or electrical dam-

age is evident when the covers

are removed.

1. Make sure input supply discon-

nect has been turned ON. Check

input fuses. Make certain that the

Power Switch (SW1) on the

power source is in the “ON” posi-

tion.

Machine will not power up (no lights) 1. No Input Power

2. Make certain that input voltage is

correct, according to the Rating

Plate located on the rear of the

machine.

2. 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.

Machine won’t weld, can’t get any 1. Input voltage is too low or too high.

output.

2. See “Thermal LED is ON”sec-

tion.

2. Thermal Error.

This problem will normally be

accompanied by an error code. See

3. Possible short in output circuit. If

condition persists, contact an

authorized Lincoln Electric Field

Service facility.

“Status Light” section of this docu- 3. Secondary current limit has been

ment for additional information.

exceeded. (see error 54)

3a. Input control board fault (see

input control board error status).

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

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E-6

TROubLEShOOTING

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PRObLEMS

(SYMPTOMS)

POSSIbLE

CAuSE

RECOMMENDED

COuRSE OF ACTION

Thermal LED is ON

Improper fan operation

basic Machine Problems (Continued)

1. Check for proper fan operation.

Fan should run in a low speed

setting when the machine is idle

and in a high speed when the

output is triggered. Check for

material blocking intake or

exhaust louvers, or for excessive

dirt clogging cooling channels in

machine.

Thermal LED is ON

1. Improper fan operation.

2. Check for broken wires, open

connections or faulty thermostats

in the thermostat circuit.

2. Open thermostat circuit.

1. Replace the battery (Type:

BS2032)

“Real Time Clock” no longer func- 1. Control PC Board Battery.

tioning

Weld and Arc Quality Problems

1. Check for feeding problems. Make

sure proper gear ratio has been

selected.

General degradation of weld perfor- 1. Wire feed problem.

mance

2. Check for bad connections,

excessive loops in cable, etc.

2. Cabling problems.

NOTE: The presence of heat in the

external welding circuit indicates

poor connections or undersized

cables.

3. Verify gas flow and type are cor-

rect.

3. Loss of, or improper Shielding

Gas.

4.Select the correct weld mode for

the application.

4. Verify weld mode is correct for

process.

5. The power source may require

calibration. (current, voltage,

WFS).

5. Machine calibration.

6. Check for feeding problems. Make

sure proper gear ratio has been

selected.

6. Wire feed problem.

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

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E-7

TROubLEShOOTING

Observe all Safety Guidelines detailed throughout this manual

PRObLEMS

(SYMPTOMS)

POSSIbLE

CAuSE

RECOMMENDED

COuRSE OF ACTION

Weld and Arc Quality Problems (Continued)

Wire burns back to tip at the end of 1. Burnback Time

the weld.

1. Reduce burnback time and/or

work point.

Machine output shuts down during a 1. Secondary current limit has been 1. Adjust procedure or reduce load

weld.

machine.

exceeded, and the machine shuts to lower current draw from the

down to protect itself.

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. Machine calibration.

1. Wire feed problem.

2. Calibrate secondary current and

voltage.

Excessively long and erratic arc.

1. Check for feeding problems. Make

sure proper gear ratio has been

selected.

2. Loss of, or improper Shielding 2. Verify gas flow and type are cor-

Gas

rect

3. Machine calibration.

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

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E-8

TROubLEShOOTING

Observe all Safety Guidelines detailed throughout this manual

PRObLEMS

(SYMPTOMS)

POSSIbLE

CAuSE

RECOMMENDED

COuRSE OF ACTION

Ethernet

Cannot Connect

1. Physical connection.

1. Verify that the correct patch cable

or cross over cable is being used

(refer to local IT department for

assistance).

1a. Verify the cables are fully 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.

3. Ethernet Speed

1. Cable Location

3. 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. 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

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F-1

Enhanced Diagram

F-1

DIAGRAMS

POWER WAVE® C300

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F-2

DIMENSION PRINT

27.43

18.80

6.93

13.94

24.04

POWER WAVE® C300

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NOTES

POWER WAVE® C300

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NOTES

POWER WAVE® C300

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l Do not touch electrically live parts or

electrode with skin or wet clothing.

l Insulate yourself from work and

ground.

l Keep flammable materials away.

l Wear eye, ear and body protection.

WARNING

Spanish

l No toque las partes o los electrodos l Mantenga el material combustible

l Protéjase los ojos, los oídos y el

bajo carga con la piel o ropa moja-

da.

l Aislese del trabajo y de la tierra.

fuera del área de trabajo.

cuerpo.

AVISO DE

PRECAuCION

French

l Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact

avec des pièces sous tension.

l Gardez à l’écart de tout matériel

inflammable.

l Protégez vos yeux, vos oreilles et

votre corps.

ATTENTION

l Isolez-vous du travail et de la terre.

German

l Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem

Körper oder feuchter Kleidung!

l Isolieren Sie sich von den

l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-

perschutz!

WARNuNG

Elektroden und dem Erdboden!

Portuguese

l Não toque partes elétricas e elec-

trodos com a pele ou roupa molha-

da.

l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e

dos.

corpo.

ATENÇÃO

l Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE

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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

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l Keep your head out of fumes.

l Use ventilation or exhaust to

remove fumes from breathing zone.

l Turn power off before servicing.

l Do not operate with panel open or

guards off.

WARNING

Spanish

l Los humos fuera de la zona de res-

piración.

l Mantenga la cabeza fuera de los

humos. Utilice ventilación o

aspiración para gases.

l Desconectar el cable de ali-

mentación de poder de la máquina

antes de iniciar cualquier servicio.

l No operar con panel abierto o

guardas quitadas.

AVISO DE

PRECAuCION

French

l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux

tien.

l Gardez la tête à l’écart des fumées.

l Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones

de travail.

ouverts ou avec les dispositifs de

protection enlevés.

ATTENTION

German

l Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff-

nen; Maschine anhalten!)

l Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in

Betrieb setzen!

l Vermeiden Sie das Einatmen von

Schweibrauch!

l Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

WARNuNG

Portuguese

l Não opere com as tampas removidas.

l Desligue a corrente antes de fazer

serviço.

l Mantenha-se afastado das partes

moventes.

l Não opere com os paineis abertos

ou guardas removidas.

l Mantenha seu rosto da fumaça.

l Use ventilação e exhaustão para

remover fumo da zona respiratória.

ATENÇÃO

l Não toque as partes elétricas nuas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS

PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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• 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 WEBꢀSITE: www.lincolnelectric.com

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