Lincoln-electric IM10038 POWER WAVE C300CE User Manual

POWER WAVE ®C300 CEOPERATOR’S MANUALIM10038Augustl, 2012Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety

PageMaintenance ...Section DSafety Precautions ...

A-1INSTALLATION POWER WAVE® C300 CEA-1TECHNICAL SPECIFICATIONS - POWER WAVE® C300 CE RECOMMENDED INPUT WIRE AND FUSE SIZES 1INPUTVOLTAGE /PHASE/FREQ

A-2INSTALLATION POWER WAVE® C300 CEA-2PHYSICAL DIMENSIONSTEMPERATURE RANGESHEIGHT18.80in (478mm)MODELK2865-1WIDTH14.00in (356mm)DEPTH27.43in (697mm)

A-3INSTALLATION POWER WAVE® C300 CEA-3SAFETY PRECAUTIONS Read this entire installation section before youstart installation.ELECTRIC SHOCK can kill.

A-4INSTALLATION POWER WAVE® C300 CEA-4INPUT CONNECTIONOnly a qualified electrician shouldconnect the input leads to thePOWER WAVE® C300 CE.Connectio

A-5INSTALLATION POWER WAVE® C300 CEA-5RECOMMENDED WORK CABLESIZES FOR ARC WELDINGA work cable is provided with the POWER WAVE®C300 CE. This cable is

A-6INSTALLATION POWER WAVE® C300 CEA-6Function12 pin connectorfor Push pullguns; foot pedal;remote controls;Hand –amptrols.PINABCDEFGHJKLMWiringCANL

A-7INSTALLATION POWER WAVE® C300 CEA-7SHIELDING GAS CONNECTIONCYLINDER may explode ifdamaged.• Keep cylinder upright andchained to support.• Keep c

PROCEDURE TO INSTALL DRIVEROLLS AND WIRE GUIDES• Turn the input power OFF at thewelding power source before instal-lation or changing drive rolls and

A-9INSTALLATION POWER WAVE® C300 CEA-9FEEDING ELECTRODE AND BRAKEADJUSTMENTDRIVE ROLL PRESSURE SETTINGELECTRIC SHOCK can kill.• Turn the input powe

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

A-10INSTALLATION POWER WAVE® C300 CEA-10TIG WELDING(Figure A.7)When TIG (GTAW) welding with the Power WaveC300CE, a torch with an integral gas valv

B-1OPERATIONPOWER WAVE® C300 CEB-1• ELECTRIC SHOCK CAN KILL.Unless using COLD FEED fea-ture, when feeding with gun trig-ger, the electrode and driveme

B-2OPERATIONB-2PRODUCT DESCRIPTIONThe POWER WAVE® C300 CE is a high performancemulti-process machine with GMAW, FCAW, SMAW,DC TIG, and pulse capabilit

B-3OPERATIONB-3DESIGN FEATURESLoaded with Standard Features• Multiple process DC output range: 5 - 300 Amps.• 208 – 575 VAC, 3 phase, 50-60Hz input

B-4OPERATIONB-4CASE FRONT CONTROLSAll operator controls and adjustments are located onthe case front of the Power Wave. (See Figure B.1)1. LEFT DISPLA

B-5OPERATIONB-5POWER WAVE® C300 CECASE BACK CONTROLS1. ETHERNET CONNECTOR2. POWER CORD3. GAS CONNECTION4. CIRCUIT BREAKER1234FIGURE B.2

B-6OPERATIONB-6INTERNAL CONTROLS1. SPINDLE BRAKE2. WIRE DRIVE PRESSURE ARM3. COLD INCH / GAS PURGE SWITCHPOWER WAVE® C300 CE123FIGURE B.3

B-7OPERATIONB-7MAKING A WELD WITH WAVEFORMTECHNOLOGY POWER SOURCESMAKING A WELDThe serviceability of a product or structure utilizing thewelding progr

B-8OPERATIONB-8POWER WAVE® C300 CEStart OptionsEnd Options Weld ModeArc ControlLESSAMPSMOREAMPSOUTPUTOFFOUTPUTON++ A AmpsWire Feed Speed (WFS)Memories

B-9OPERATIONB-9SMAW (STICK) WELDINGSMAW is most often used for outdoor construction,pipe welding and general repairs. The POWERWAVE® C300 CE controls

ARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when welding or obs

B-10OPERATIONB-10NON-SYNERGIC GMAW AND FCAWWELDINGIn non-synergic modes, the WFS control is similar to aconventional CV power source where WFS and vol

B-11OPERATIONB-11GMAW (MIG) SYNERGIC WELDINGIn synergic welding modes, WFS is the dominant controlparameter. For each wire feed speed, a correspondin

B-12OPERATIONB-12POWER WAVE® C300 CESTEEL AND STAINLESS SYNERGIC GMAW-P (PULSED MIG) WELDINGWhen pulse welding, the power source primarily regu-lates

B-13OPERATIONB-13STEEL AND STAINLESS GMAW-P(PULSED MIG) WELDINGPOWER WAVE® C300 CELessDepositionMoreDepositionShorterArcLongerArc++ AMPSWFSVOLTS TRIM4

B-14OPERATIONB-14POWER WAVE® C300 CEALUMINUM SYNERGIC GMAW-P(PULSED MIG)AND GMAW-PP(PULSE ON PULSE) WELDINGThe POWER WAVE® C300 CE can produce top qua

B-15OPERATIONB-15POWER WAVE® C300 CEALUMINUM GMAW-P (PULSED MIG)AND GMAW-PP (PULSE ON PULSE)WELDINGLessDepositionMoreDepositionShorterArcLongerArc++ A

B-16OPERATIONB-16POWER WAVE® C300 CEGTAW (TIG) WELDINGThe POWER WAVE® C300 CE is excellent for(Touch Start TIG) welding.OUTPUTONOUTPUTOFF++ AMPSWFSVOL

B-17OPERATIONB-17RECALLING A MEMORY To recall the selected memory, press and hold cen-ter knob for (1 second). After recalling a memory, amessage wil

B-18OPERATIONB-18Press the Left Push Button until Memory 'M' LEDis illuminated.Rotate center knob to cycle to desired memory.Press and hold

B-19OPERATIONB-19POWER WAVE® C300 CE1 SECONDPress1 SECONDPress1. Rotate center knob to select parameter to be set(WFS, Voltage, Trim).2. Press the Lef

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

B-20OPERATIONB-20POWER WAVE® C300 CE2-STEP 4-STEP- TRIGGEROPERATIONThe 2-Step - 4-Step switch changes the function ofthe gun trigger. 2-Step trigger

B-21OPERATIONB-21POWER WAVE® C300 CEEXAMPLE 1 - 2 STEP TRIGGER: Simple operationThe simplest trigger operation occurs with a 2 Steptrigger and the Sta

B-22OPERATIONB-22POWER WAVE® C300 CEEXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Startand Arc End. Tailoring the arc start and arc end is acommon method f

B-23OPERATIONB-23POWER WAVE® C300 CEWELD:After upslope, the power source output and the wirefeed speed continue at the weld settings.CRATER & DOWN

B-24OPERATIONB-24POWER WAVE® C300 CEShieldingGasIdle Preflow Strike WeldBurnback Postflow Idl eWFSOnOffRu n-inOffWe ldOffWe ldArc EstablishedTrigger P

B-25OPERATIONB-25POWER WAVE® C300 CEEXAMPLE 5 - 4 STEP TRIGGER: Manual control ofStart and Crater times with Burnback ON. The 4 steptrigger sequence g

B-26OPERATIONB-26POWER WAVE® C300 CECOLD FEED/GAS PURGE SWITCHCold Feed and Gas Purge are com-bined into a single spring centered tog-gle switch.To ac

B-27OPERATIONB-27POWER WAVE® C300 CESET-UP FEATURES MENU(See Figure B.16)1. To access the set-up menu, press the Right andLeft buttons of the Main Dis

B-28OPERATIONB-28POWER WAVE® C300 CEUSER DEFINED PARAMETERSParameter DefinitionExit Setup MenuP. 0This option is used to exit the setup menu. When P.0

B-29OPERATIONB-29POWER WAVE® C300 CEUSER DEFINED PARAMETERSParameter DefinitionP.5 Procedure Change MethodThis option selects how remote procedure sel

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dan

B-30OPERATIONB-30POWER WAVE® C300 CEUSER DEFINED PARAMETERSParameter DefinitionP.7 Gun Offset AdjustmentThis option adjusts the wire feed speed calibr

B-31OPERATIONB-31POWER WAVE® C300 CEUSER DEFINED PARAMETERSParameter DefinitionP.16 Push-Pull Gun Knob BehaviorThis option determines how the potentio

B-32OPERATIONB-32POWER WAVE® C300 CEParameter DefinitionP.22 Arc Start/Loss Error TimeThis option can be used to optionally shut off output if an arc

B-33OPERATIONB-33POWER WAVE® C300 CEUSER DEFINED PARAMETERSParameter DefinitionP.27 Language SelectSelects which language will be displayed on the Use

B-34OPERATIONB-34POWER WAVE® C300 CEUSER DEFINED PARAMETERSParameter DefinitionP.102 View Fatal LogsUsed for viewing all the system fatal logs. Press

B-35OPERATIONB-35POWER WAVE® C300 CEUSER DEFINED PARAMETERSParameter DefinitionP.502 Memory Change LockoutDetermines if the memories can be overwritte

WIRE FEEDER OPTIONSK2490-1 MAGNUM®250LX SPOOL GUNAir-Cooled, 25 ft. 280 amps,60% dutycycle Feeds .025”-3/64” (0.6-1.2mm)diameter aluminum wire on 2lbs

D-1MAINTENANCED-1POWER WAVE® C300 CESAFETY PRECAUTIONSWARNINGELECTRIC SHOCK can kill.•Do not operate with coversremoved.•Turn off power source beforei

E-1TROUBLESHOOTINGE-1POWER WAVE® C300 CEIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,

E-2TROUBLESHOOTINGE-2POWER WAVE® C300 CEIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,

vvSAFETYElectromagnetic Compatibility (EMC)ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 1

E-3TROUBLESHOOTINGE-3POWER WAVE® C300 CEObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-4TROUBLESHOOTINGE-4POWER WAVE® C300 CEObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-5TROUBLESHOOTINGE-5POWER WAVE® C300 CEObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-6TROUBLESHOOTINGE-6POWER WAVE® C300 CEObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-7TROUBLESHOOTINGE-7POWER WAVE® C300 CEObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

E-8TROUBLESHOOTINGE-8POWER WAVE® C300 CEObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test

F-1WIRING DIAGRAMF-1POWER WAVE® C300 CENOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. T

F-2DIMENSION PRINTF-2POWER WAVE® C300 CE

NOTES POWER WAVE® C300 CE

NOTES POWER WAVE® C300 CE

viviSAFETYElectromagnetic Compatibility (EMC)The size of the surrounding area to be considered will depend on the structure of the building and othera

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

Need Help?Lincoln Electric “Rapid Response” Service!Call 1.888.935.3877 to talk to a Service RepresentativeHours of Operation: 8:00 A.M. to 6:00 P.M.

viiviiThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as

viiiviiiTABLE OF CONTENTSPageInstallation...........................