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Lincoln Electric POWER WAVE 300C, Operator'S Manual

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Lincoln Electric POWER WAVE 300C Operator'S Manual Download Page 9

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

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

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

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

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

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   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

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

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

TABLE OF CONTENTS

Summary of Contents for POWER WAVE 300C

Page 1: ...er Authorized Service and Distributor Locator www lincolnelectric com locator IM10591 Issue Date Oct 20 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 12942 12943 129...

Page 2: ...A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual s...

Page 3: ...t engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and d...

Page 4: ...m to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with s...

Page 5: ...nt passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow N...

Page 6: ...i s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pant...

Page 7: ...t 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 addit...

Page 8: ...A 11 ________________________________________________________________________________ Operation Section B Safety Precautions B 1 Graphic Symbols B 1 Power Up Sequence B 1 Duty Cycle B 1 Product Descri...

Page 9: ...ng 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 ___________________...

Page 10: ...100 40 100 40 100 Process GMAW GMAW Pulse FCAW SMAW GTAW DC Maximum Input Amperes 1 Phase in parenthesis 39 35 22 18 14 5 57 52 NA NA NA Idle Power N A Power Factor Rated Output N A Input Voltage 10...

Page 11: ...00 40 100 40 100 Process GMAW GMAW Pulse FCAW SMAW GTAW DC Maximum Input Amperes 1 Phase in parenthesis 44 40 25 20 16 5 61 58 NA NA NA Idle Power N A Power Factor Rated Output N A Input Voltage 10 20...

Page 12: ...DC average 74V peak 24 VDC average 45V peak 60 VDC average 65V peak WIRE SPEED RANGE WELDING PROCESS WIRE FEED SPEED RANGE WIRE SIZE WFS RANGE 50 800 ipm 1 3 17 8 m min WIRE SIZES 025 045 0 6 1 1mm GM...

Page 13: ...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...

Page 14: ...n nuisance shut offs from welder inrush currents even if the machine is not being used at high currents INPUT VOLTAGE SELECTION The POWER WAVE 300C automatically adjusts to work with different input v...

Page 15: ...put 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 outpu...

Page 16: ...this Instruction Manual 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 Whenever possible always weld in a direction away f...

Page 17: ...ding 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...

Page 18: ...ark 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...

Page 19: ...thumb screw hole in the feed plate Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned 10 Tighten the socket head cap screw 11 Insert the welding gun into...

Page 20: ...anels or guards removed or open Only qualified personnel should perform mainte nance work The POWER WAVE 300C s optimum drive roll pres sure varies with type of wire surface condition lubri cation and...

Page 21: ...pplications connect the stick electrode holder to the positive output stud standard model or electrode stud advanced model and connect the work clamp to the negative output stud standard model or elec...

Page 22: ...TION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN UAL WARNING SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE Standard Model Standard Mode...

Page 23: ...ities are supported 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 connec...

Page 24: ...leshooting Potted PC boards for enhanced ruggedness reliabili ty Remote control Foot amptrol ready Waveform Control Technology for good weld appearance and low spatter even when welding nickel alloys...

Page 25: ...NOB Use to Navigate Select settings or process 4 MAIN DISPLAY Shows detailed welding process information 5 PROCESS SELECTION BUTTONS Quick common procedures selection 6 MEMORY SELECTION BUTTONS Use to...

Page 26: ...avigate Select settings or process 4 MAIN DISPLAY Shows detailed welding process information 5 PROCESS SELECTION BUTTONS Quick common procedures selection 6 MEMORY SELECTION BUTTONS Use to save up to...

Page 27: ...ODELS 1 POWER CORD LOCATION 2 GAS CONNECTION GMAW AND FCAW 3 GAS CONNECTION GTAW 4 OPTIONAL 115 VOLT 10 AMPS 60 Hz RECEPTACLE FOR GENERAL USE K2829 1 FIGURE B 3 POWER WAVE 300C OPERATION B 6 5 CIRCUIT...

Page 28: ...E DRIVE PRESSURE ARM 3 THUMB SCREW FOR SECURING THE WELDING GUN 4 GUN BUSHING 5 SOCKET HEAD CAP SCREW FOR SECURING THE GUN BUSHING 6 GAS CONNECTION GMAW OR FCAW GUN 7 CIRCUIT BREAKER 8 COLD INCH GAS P...

Page 29: ...welding mode offers the simplicity of single knob control The machine will select the cor rect voltage and amperage based on the wire feed speed WFS set by the operator BASIC WELDING CONTROLS WELD MO...

Page 30: ...his will deac vate all outputs besides the TIG output 6 FCAW Bu on Press to set the system to FCAW mode This will deac vate all outputs besides the FCAW output 7 MIG Bu on Press to set the system to M...

Page 31: ...op ons along the bo om of the screen Press the knob to select the highlighted op on 3 Wire Feed Speed Se ng Sets the desired wire feed speed 4 Voltage Se ng Sets the voltage 5 Weld Mode 6 Wire Diamet...

Page 32: ...n 2 Current Se ng Sets the desired current use le knob to adjust to adjust the allowable ranges to be set by a remote 3 Weld Mode 4 Output Indicator Note Output is ON at all mes in S ck process POWER...

Page 33: ...se le knob to adjust 4 Output Indicator Output will be on in Touch Start mode without a remote Output will be o un l triggered when a remote is connected Note HF mode requires a remote to be connected...

Page 34: ...t Time Controls the voltage for a speci ed me at the beginning of the weld During that me the machine will ramp from the Start Procedure to the Welding Procedure 3 Crater Time Controls the voltage for...

Page 35: ...n 3 Wire Feed Speed Se ng Sets the desired wire feed speed use le knob to adjust 4 Voltage Se ng Sets the voltage use right knob to adjust 5 Wire Diameter Selec on 6 Gas Type Selec on 7 Weld Mode 8 Wi...

Page 36: ...2 Step 4 Step Trigger Interlock Toggles between 2 Step and 4 Step Trigger Interlock 2 Step provides weld power and feeds wire only when the trigger is depressed 4 Step eliminates the need to hold the...

Page 37: ...on is available in MIG and FCAW modes 3 Pre Flow Time Adjusts the me that shielding gas ows before the welding output turns on 4 Start Time Controls the WFS and Volts for a speci ed me at the beginnin...

Page 38: ...y Media Connected 2 Memories View the saved memories for each process 3 Language Allows the user interface to be translated into the user s preferred language 4 Display Units Allows units to be displa...

Page 39: ...OPERATION B 18 ADVANCED SYSTEM SETTINGS FIGURE B 13 1 So ware Versions 2 Weld Feedback Persists 3 Weld Feedback Time 4 Home Screen Layout Choose between Advanced and Simpli ed POWER WAVE 300C 1 2 3 4...

Page 40: ...se ngs will appear here Each weld process will have di erent se ngs The most common advanced se ngs are Pinch Arc Force Hot Start Pre Flow Time Post Flow Time 2 Step 4 Step Trigger and Ul marc Advanc...

Page 41: ...1 Pinch Se ng 2 Previous Se ng Indicator The do ed line will indicate where on the bar the most recent se ng was 3 Pinch Se ng Indicator Increasing the value will move the bar to the right decreasing...

Page 42: ...Name 2 Weld Feedback Current 3 Weld Feedback Voltage POWER WAVE 300C 2 5 4 3 1 4 Ac ve Weld Se ngs 5 Dual Procedure Indicator Displays the ac ve welding procedure schedule Pressing the ac ve process b...

Page 43: ...R WAVE 300C OPERATION B 22 BACK HOME BUTTONS FIGURE B 18 1 Back Bu on Selec ng the back bu on takes the system back one screen 2 Home Bu on Selec ng the home bu on takes the system back to the home sc...

Page 44: ...out If the memory bu on is pressed again the se ngs will revert to the se ngs saved in the memory Four dis nct memories can be saved for each process to the 4 memory bu ons on the User Interface 4 for...

Page 45: ...10 0 PINCH CONTROLS THE ARC CHARACTERISTICS WHEN SHORT ARC WELDING MIG ULTIMARC SOFT 10 0 TO STIFF 10 0 ULTIMARC REGULATES THE FOCUS OR SHAPE OF THE ARC ULTIMARC VALUES GREATER THAN 0 0 INCREASE THE P...

Page 46: ...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...

Page 47: ...d 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...

Page 48: ...nslope Crater Crater ti me Power Source Output Crater FIGURE B 22 EXAMPLE 3 2 STEP TRIGGER Customized Arc Start Crater and Arc End Sometimes it is advanta geous to set specific arc start crater and ar...

Page 49: ...is pulled a second time and then released or if the arc is interrupted See Figure B 23 For this sequence PREFLOW Shielding gas begins to flow immediately when the gun trigger is pulled RUN IN After pr...

Page 50: ...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 WE...

Page 51: ...he WFS knob Cold feeding or cold inching the electrode is useful for threading the electrode through the gun Hold with toggle switch in the BACK position to acti vate Gas Purge and let the shielding g...

Page 52: ...llows guns with a Fast Mate style back end to connect into Power Wave 300C and Power MIG power sources Order K489 8 REMOTE OUTPUT CONTROL WITH 12 PIN UNIVERSAL CONNECTOR Consists of a control box with...

Page 53: ...djustment 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...

Page 54: ...ended Course of Action safely contact your local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trai...

Page 55: ...conditions are indicated in the following Table E 1 Light Condition Steady Green Blinking Green Fast Blinking Green Alternating Green and Red Steady Red Blinking Red Status LED off Input control boar...

Page 56: ...econdary current limit is 325 amps 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...

Page 57: ...over current Other Indication Input current limit has been exceeded Typically indicates short term power overload If problem persists contact Service Department 15 VDC supply on Input control board to...

Page 58: ...low or too high 1 Input voltage is too low or too high 2 Thermal Error 3 Secondary current limit has been exceeded see error 54 3a Input control board fault see input control board error status 1 Mak...

Page 59: ...eck 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 fo...

Page 60: ...Input voltage may be too low lim iting output capability of the power source 2 Machine calibration 1 Wire feed problem 2 Loss of or improper Shielding Gas 3 Machine calibration 1 Reduce burnback time...

Page 61: ...ble 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...

Page 62: ...33 32A 32 GND5 10A 408 407 406 404 403 402 401 351 354 353 348 347 346 345 344 343 342 341 409 410 224 222 223 221 224 222 223 221 214 211 213 212 351 354 353 350 355 356 358 51 52 554A 555A 396A 67C...

Page 63: ...B R Y N U FAN G B R Y N U FAN G B R Y N U FAN G B R Y N U FAN G 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 TACH MOTOR B R B U R Y 1J31 2J31 3J31 4J31 1M12 2M12 USB UI MODULE 11J32 13J32 14J32 12J32 1J62 2J62 3J6...

Page 64: ...POWER WAVE 300C DIMENSION PRINT F 3 39 67 20 51 39 44 25 92 25 70...

Page 65: ...POWER WAVE 300C NOTES...

Page 66: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra...

Page 67: ...d Entl ftung des Arbeitsplatzes l Mantenha seu rosto da fuma a l Use ventila o e exhaust o para remover fumo da zona respirat ria l Turn power off before servicing l Desconectar el cable de ali mentac...

Page 68: ...tomer 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...

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