Instruction/ maintenance manual of the product C300 CE Lincoln Electric
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• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b.
FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. I ns t al l equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations.
PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1.
THIS SAMPLE DOCUMENT IS USED FOR “CE” MACHINES ONL Y! v v 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.
THIS SAMPLE DOCUMENT IS USED FOR “CE” MACHINES ONL Y! vi vi 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.
vii vii Thank Y ou 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! Read this Operators Manual completely before attempting to use this equipment.
viii viii T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .................................................
Page Maintenance ....................................................................................................Section D Safety Precautions .........................................................................................................
A-1 INST ALLA TION POWER WAVE® C300 CE A-1 TECHNICAL SPECIFICA TIONS - POWER W A VE® C300 CE RECOMMENDED INPUT WIRE AND FUSE SIZES 1 INPUT VOLTAGE / PHASE/ FREQUENCY 208/3/50/60 230/3/50/60 400/3/50/60 460/3/50/60 575/3/50/60 TIME DELAY FUSE OR BREAKER SIZE 2 (AMPS) 40 40 25 20 15 CORD SIZES 3 AWG SIZES (mm 2 ) 8 (10) 8 (10) 12 (4) 14 (2.
A-2 INST ALLA TION POWER WAVE® C300 CE A-2 PHYSICAL DIMENSIONS TEMPERA TURE RANGES HEIGHT 18.80in (478mm) MODEL K2865-1 WIDTH 14.00in (356mm) DEPTH 27.
A-3 INST ALLA TION POWER WAVE® C300 CE A-3 SAFETY PRECAUTIONS Read this entire installation section before you start installation. ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.
A-4 INST ALLA TION POWER WAVE® C300 CE A-4 INPUT CONNECTION Only a qualified electrician should connect the input leads to the POWER WAVE® C300 CE. Connections should be made in accordance with all local and national electrical codes and the connection dia- gram located on the inside of the reconnect access door of the machine.
A-5 INST ALLA TION POWER WAVE® C300 CE A-5 RECOMMENDED WORK CABLE SIZES FOR ARC WELDING A work cable is provided with the POWER WAVE® C300 CE. This cable is appropriately sized for all of the POWER WAVE® C300 CEʼs welding procedures.
A-6 INST ALLA TION POWER WAVE® C300 CE A-6 Function 12 pin connector for Push pull guns; foot pedal; remote controls; Hand –amptrols. PIN A B C D E F G H J K L M Wiring CANL CANH Remote Pot Common Remote Pot Wiper Remote Pot +10VDC ArcLink Peripheral Sense Trigger Trigger Power Common Power + Motor Negative Motor Positive TABLE A.
A-7 INST ALLA TION POWER WAVE® C300 CE A-7 SHIELDING GAS CONNECTION CYLINDER may explode if damaged. • Keep cylinder upright and chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached.
PROCEDURE T O INST ALL DRIVE ROLLS AND WIRE GUIDES • Turn the input power OFF at the welding power source before instal- lation or changing drive rolls and/or guides.
A-9 INST ALLA TION POWER WAVE® C300 CE A-9 FEEDING ELECTRODE AND BRAKE ADJUSTMENT 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.
A-10 INST ALLA TION POWER WAVE® C300 CE A-10 TIG WELDING (Figure A.7) When TIG (GTAW) welding with the Power Wave C300CE, a torch with an integral gas valve is required.
B-1 OPERA TION POWER WAVE® C300 CE B-1 • 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.
B-2 OPERA TION B-2 PRODUCT DESCRIPTION The POWER WAVE® C300 CE is a high performance multi-process machine with GMAW, FCAW, SMAW, DC TIG, and pulse capability. It will offer a premier welding performance solution for specific areas such as aluminum, stainless, nickel where size and weight are an issue.
B-3 OPERA TION B-3 DESIGN FEA TURES Loaded with Standard Features • Multiple process DC output range: 5 - 300 Amps. • 208 – 575 VAC, 3 phase, 50-60Hz input power. • New and Improved Line Voltage Compensation holds the output constant over wide input voltage fluctuations.
B-4 OPERA TION B-4 CASE FRONT CONTROLS All operator controls and adjustments are located on the case front of the Power Wave. (See Figure B.1) 1. LEFT DISPLAY- Shows wire feed speed or amper- age, 2. LEFT KNOB - Adjusts value in left display. 3. MAIN DISPLAY - Shows detailed welding and diag- nostic information.
B-5 OPERA TION B-5 POWER WAVE® C300 CE CASE BACK CONTROLS 1. ETHERNET CONNECTOR 2. POWER CORD 3. GAS CONNECTION 4. CIRCUIT BREAKER 1 2 3 4 1 2 3 4 FIGURE B.
B-6 OPERA TION B-6 INTERNAL CONTROLS 1. SPINDLE BRAKE 2. WIRE DRIVE PRESSURE ARM 3. COLD INCH / GAS PURGE SWITCH POWER WAVE® C300 CE 1 2 3 1 2 3 FIGURE B.
B-7 OPERA TION B-7 MAKING A WELD WITH W A VEFORM TECHNOLOGY POWER SOURCES MAKING A WELD The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs.
B-8 OPERA TION B-8 POWER WAVE® C300 CE Start Options End Options Weld Mode Arc Control LESS AMPS MORE AMPS OUTPUT OFF OUTPUT ON + + A Amps Wire Feed Speed (WFS) Memories Trigger Options V Volts Trim .
B-9 OPERA TION B-9 SMA W (STICK) WELDING SMAW is most often used for outdoor construction, pipe welding and general repairs. The POWER WAVE® C300 CE controls Amperage, Output Control and Arc Force during SMAW welding. During SMAW welding the wire drive remains idle.
B-10 OPERA TION B-10 NON-SYNERGIC GMA W AND FCA W WELDING 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.
B-11 OPERA TION B-11 GMA W (MIG) SYNERGIC WELDING In synergic welding modes, WFS is the dominant control parameter. For each wire feed speed, a corresponding volt- age is programmed into the machine at the factory. The user adjusts WFS according to factors such as wire size, material thickness, penetration requirements, etc.
B-12 OPERA TION B-12 POWER WAVE® C300 CE STEEL AND ST AINLESS SYNERGIC GMA W-P (PULSED MIG) WELDING Trim .50 Arc Len g th Short Trim 1.00 Arc Len g th Medium Trim 1.50 Arc Length Long Tr im . 5 0 Ar c Len g th Sh ort Tr im 1 . 0 0 Arc L e n g th M e diu m Tr im 1.
B-13 OPERA TION B-13 STEEL AND ST AINLESS GMA W-P (PULSED MIG) WELDING POWER WAVE® C300 CE Less Deposition More Deposition Shorter Arc Longer Arc + + AMPS WFS VOL TS TRIM 4.50 0.0 STEEL 1.0mm 12 EFFECT / RANGE -10.0 (SOFT to 0 to 120.0 Seconds OFF, 0.
B-14 OPERA TION B-14 POWER WAVE® C300 CE ALUMINUM SYNERGIC GMA W-P (PULSED MIG)AND GMA W-PP (PULSE ON PULSE) WELDING The POWER WAVE® C300 CE can produce top qual- ity aluminum welds with excellent appearance, little spatter and good bead shape.
B-15 OPERA TION B-15 POWER WAVE® C300 CE ALUMINUM GMA W-P (PULSED MIG) AND GMA W-PP (PULSE ON PULSE) WELDING Less Deposition More Deposition Shorter Arc Longer Arc + + AMPS WFS VOL TS TRIM 4 .5 0.0 72 EFFEC T / R A NGE PU LS E PU LS E-ON-PU LS E FREQUENCY: FREQ .
B-16 OPERA TION B-16 POWER WAVE® C300 CE GT A W (TIG) WELDING The POWER WAVE® C300 CE is excellent for (Touch Start TIG) welding. OUTPUT O N OUTPUT OFF + + AMPS WFS VOL TS TRIM 50 OFF 3 TOU C H START TI G No UltimArc™ Control are active for Touch Start TIG.
B-17 OPERA TION B-17 RECALLING A MEMOR Y To recall the selected memory, press and hold cen- ter knob for (1 second) . 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.
B-18 OPERA TION B-18 Press the Left Push Button until Memory 'M' LED is illuminated. Rotate center knob to cycle to desired memory. Press and hold center knob for 5 seconds. The Set Limits Menu will be active. POWER WAVE® C300 CE LIMITS Limits allow the welder to adjust the welding proce- dure only within a defined range.
B-19 OPERA TION B-19 POWER WAVE® C300 CE 1 S E CO ND Press 1 S E CO ND Press 1. Rotate center knob to select parameter to be set (WFS, Voltage, Trim). 2. Press the Left pushbutton to select the limit to be set (High, Nominal, Low). The selected value will blink.
B-20 OPERA TION B-20 POWER WAVE® C300 CE 2-STEP 4-STEP- TRIGGER OPERA TION 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.
B-21 OPERA TION B-21 POWER WAVE® C300 CE 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.
B-22 OPERA TION B-22 POWER WAVE® C300 CE 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.
B-23 OPERA TION B-23 POWER WAVE® C300 CE 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.
B-24 OPERA TION B-24 POWER WAVE® C300 CE Shield in g Ga s I dl e P r e f l ow S t r ik e W e l d Bu rn b ack Po st f lo w I d l e WFS On Of f Ru n- in Of f We l d Of f We l d Arc Established T rigger Pulled T rigger Released 4 St ep T rigg e r St art = O FF C rater = OFF B u rnb ack = OF F 1.
B-25 OPERA TION B-25 POWER WAVE® C300 CE 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.
B-26 OPERA TION B-26 POWER WAVE® C300 CE COLD FEED/GAS PURGE SWITCH Cold Feed and Gas Purge are com- bined into a single spring centered tog- gle switch. To activate Cold Feeding, hold the switch in the UP position. The wire drive will feed electrode but neither the power source nor the gas solenoid will be energized.
B-27 OPERA TION B-27 POWER WAVE® C300 CE SET -UP FEA TURES MENU (See Figure B.16) 1. To access the set-up menu, press the Right and Left buttons of the Main Display panel simultane- ously. Note that the set-up menu cannot be accessed if the system is welding, or if there is a fault (The status LED is not solid green).
B-28 OPERA TION B-28 POWER WAVE® C300 CE USER DEFINED P ARAMETERS Parameter Definition Exit Setup Menu P. 0 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 Wire Feed Speed Units This option selects which units to use for displaying wire feed speed.
B-29 OPERA TION B-29 POWER WAVE® C300 CE USER DEFINED P ARAMETERS Parameter Definition P .5 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.
B-30 OPERA TION B-30 POWER WAVE® C300 CE USER DEFINED P ARAMETERS Parameter Definition P .7 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.
B-31 OPERA TION B-31 POWER WAVE® C300 CE USER DEFINED P ARAMETERS Parameter Definition P .16 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).
B-32 OPERA TION B-32 POWER WAVE® C300 CE Parameter Definition P .22 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.
B-33 OPERA TION B-33 POWER WAVE® C300 CE USER DEFINED P ARAMETERS Parameter Definition P .102 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.
B-34 OPERA TION B-34 POWER WAVE® C300 CE USER DEFINED P ARAMETERS Parameter Definition P .503 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.
B-35 OPERA TION B-35 POWER WAVE® C300 CE USER DEFINED P ARAMETERS Parameter Definition P .507 UI Clear All Memories Allows the operator to quickly set all memories to the default weld mode and welding parame- ters. Presently, this option does not exist in any setup menu.
WIRE FEEDER OPTIONS K2490-1 MAGNUM ® 250LX SPOOL GUN Air-Cooled, 25 ft. 280 amps,60% duty cycle Feeds .025”-3/64” (0.6-1.2mm) diameter aluminum wire on 2lbs. (0.9kg.) spool. The Magnum 250LX spool gun is a professional grade solution for feeding small spools of aluminum and steel wire.
D-1 MAINTENANCE D-1 POWER WAVE® C300 CE SAFETY PRECAUTIONS W ARNING 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.
E-1 TROUBLESHOOTING E-1 POWER WAVE® C300 CE 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.
E-2 TROUBLESHOOTING E-2 POWER WAVE® C300 CE 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.
E-3 TROUBLESHOOTING E-3 POWER WAVE® C300 CE Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-4 TROUBLESHOOTING E-4 POWER WAVE® C300 CE Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-5 TROUBLESHOOTING E-5 POWER WAVE® C300 CE Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-6 TROUBLESHOOTING E-6 POWER WAVE® C300 CE Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-7 TROUBLESHOOTING E-7 POWER WAVE® C300 CE Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-8 TROUBLESHOOTING E-8 POWER WAVE® C300 CE Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
F-1 WIRING DIAGRAM F-1 POWER WAVE® C300 CE NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
F-2 DIMENSION PRINT F-2 POWER WAVE® C300 CE.
NOTES POWER WAVE® C300.
NOTES POWER WAVE® C300.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁ TICAS DE SEGURANÇA DO EMPREGADOR.
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.
An important point after buying a device Lincoln Electric C300 CE (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric C300 CE yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric C300 CE - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric C300 CE you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric C300 CE will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric C300 CE, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric C300 CE.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric C300 CE. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric C300 CE along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
