POWERWAVE C300
Contents
1. TVZZTZZTTTZTZTTTTTTTTTTTTTT 1 ETHERNET CONNECTOR 2 GAS CONNECTION 3 POWER CORD POWERWAVE C300 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo 919 gt 0 9 8 o ojeg 5 2 Do Return to Section TOC Return to Master TOC OPERATION INTERNAL CONTROLS Code 11479 FIGURE B 3 1 SPINDLE BRAKE 2 WIRE 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 4 PIN TRIGGER RECEPTACLE 12 7 POSITIVE STUD 8 GAS CONNECTION 9 NEGATIVE STUD 10 COLD INCH GAS PURGE SWITCH 11 6 PIN CONNECTOR FOR REMOTE CONTROL OPTIONS 12 7 PIN CONNECTOR FOR PUSH PULL OR SPOOL GUN OPTIONS POWERWAVE C300 LINCOLN B OPERATION 7 CASE FRONT CONTROLS USED O OWIRE FEED SPEED WFS eC VOLTS AMPS oL 65 TRIM RG MORE M id E AMPS AMPS OFF C setup IR PORT Return to Section TOC Return to Master TOC START OPTIONS OPTIONS DUAL PROCEDURE MEMORY PANEL OPERA TION Return to Section TOC Return to Master TOC ojo 919 0 9 FEE gt ojeg 5 2 o Return to Section TOC Return to Master TOC POWERWAVE C300 LINCOLN Return to Section TOC Return to Master TOC Return2. display will show the following Four items show on the MSP4 panel Memory Value High Limit 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 200 setup 200 10 180 IR PORT WELD WFS START OPTIONS wELDMODE UltimArc Control END OPTIONS Press to select item to change Rotate to Change Value The Limits Setup menu shows a list of all parameters available for the weld mode stored in the memory cho sen For example if limits are being set for a stick SMAW mode parameters such as Run in WFS and Postflow will not appear To lock a parameter to a specific value that cannot be changed set the high and low limits to the same value The memory value must always be less than or equal to the high limit and greater than or equal to the low limit 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 but ton YES to save and enable the limits and exit Press the right MSP4 button NO to exit and leave limits unchanged Enabling Disabling Limits Enable Disable Limits Press 10 seconds Limits for each memory be ena
3. Return to Master TOC Return to Master TOC o 5 gt B Return to Master View Safety Info View Safety Info View Safety Info View Safety Info SVM1XX A X 2009 POWERWAVE C300 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machine code number 111XX SERVICE MANUAL LI NCOLN e Copyright O Lincoln Global Inc 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 WEB SITE www lincolnelectric com Return to Section TOC Return to Master TOC Return to Section TOC Cfi 0 9 Ae o 5 2 Dio cio Return to Section TOC Return to Master TOC Return to Master TOC 2 SHIELDING GAS CONNECTION A WARNING CYLINDER may explode if damaged e Keep cylinder upright and chained to support Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never all
4. bled or disabled by pressing and hold the appropriate memory button for 10 seconds Release the memory button when the MSP4 display shows the following setup PORT MEMORY 2 LIMITS ENABLE DISABLE WELD MODE START OPTIONS lItimArc Control 9 END OPTIONS 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 C setup ENABLE LIMITS V Yes No IR PORT WELD MODE START OPTIONS UltimArc Control END OPTIONS 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 POWERWAVE C300 LINCOLN B
5. ches 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 puddle Pulse welding controls the arc length with Trim instead of voltage When trim arc length is adjusted the Power Wave automatically recalculates the voltage current and time of each part of the pulse waveform 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 See Figure B 10 FIGURE B 10 Trim 1 50 Arc Length Long Trim 1 00 Arc Length Medium Trim 50 Arc Length Short POWERWAVE C300 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Cfi 0 9 oe o ojeg 5 2 Dio cio Return to Section TOC Return to Master TOC 3 OPERATION 3 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 Memory Value Low Limit High Limit C setup IR PORT 2200 LO 180 WELD WFS START OPTIONS END OPTIONS WELD MODE UltimArc Control 5 Parameter If the passcode has been set to zero 0000 SETUP will illuminate on the MSP4 panel and the
6. e stick electrode holder to the positive output stud and connect the work clamp to the negative output stud Some SMAW welding procedures does 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 ian Uem SA Ld SPOOL GUN N PUSH PULL RECEPTACLE REMOTE CONTROL RECEPTACLE POSITIVE STUD GAS SUPPLY CONNECTION N M NEGATIVE N STUD Tes n lt 7 N TO POSITIVE STUD 4 WORK CLAMP WORK PIECE TO iD a 7 STUD Tig GASHOSE FOOT AMPTROL OPTIONAL TO GAS SUPPLY 7 CONNECTION 2 REMOTE CONTROL RECEPTACLE POWERWAVE C300 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC ojo 919 gt 0 9 5 8 o ojeg 5 2 Do Return to Section TOC Return to Master TOC Return to Master TOC OPERATION CASE FRONT CONTROLS Code 11479 FIGURE B 1 All operator controls and adjustments are located on the case fro
7. gas inlet Tighten the union nuts with a wrench Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released 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 The flow regulator is adjustable Adjust it to the flow rate recommended for the procedure and process being used before making a weld POWER WAVE C300 s internal gas connection should be connected to wire drive s gas connection FIGURE A 4 ENTERNAL GAS CONNECTION FOR GMAW PROCESS POWERWAVE C300 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 919 0 9 D 8 o ojeg 5 2 Return to Section TOC Return to Master TOC 3 INSTALLATION 3 TIG WELDING Figure A 7 Tig uses Electrode Negative Polarity so for this appli cation connect the Tig torch to the negative output stud and connect the work clamp to the positive output stud The TIG torches 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 SMAW WELDING Most SMAW welding procedures use Electrode Positive welding For these applications connect th
8. nt 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 4 LEFT BUTTON Changes the Main display to show the Weld Mode or Arc Control 5 MAIN KNOB Changes the values on the Main dis play 6 PROCEDURE BUTTON Selects A or B procedure 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 9 ON OFF SWITCH Controls power to the Power Wave C300 10 RIGHT DISPLAY Shows voltage or trim 11 THERMAL LIGHT Indicates when machine has thermal fault 12 RIGHT KNOB Adjusts value in right display 13 SET UP Lights when machine is in set up mode 14 IR PORT Used to transfer information to palm computers etc 15 RIGHT BUTTON Used to toggle start options and to end options POWERWAVE C300 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC 919 ojeg 8 gt 9 5 2 Return to Section TOC Return to Master TOC Return to Master TOC 5 OPERATION CASE BACK CONTROLS Code 11479 FIGURE B 2
9. ow welding electrode to touch cylinder Keep cylinder away from welding or other live electrical circuits BUILD UP OF SHIELDING GAS MAY E HARM HEALTH OR KILL o 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 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 INSTALLATION 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 supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 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 Attach the flow regulator to the cylinder valve and tight en the union nut s securely with a wrench Note if connecting to 100 CO cylinder insert regulator 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 Attach one end of the inlet hose to the outlet fitting of the flow regulator Attach the other end to the welding System shielding
10. to Section TOC Return to Master TOC e ci gt og 5 8 gt 5 2 Return to Section TOC Return to Master TOC i OPERATION 8 ALUMINUM SYNERGIC GMAW P PULSED MIG JAND GMAW PP PULSE ON PULSE WELDING 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 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 The pulsing frequency is adjustable Changing the fre quency modulation or arc control of the waveform changes the ripple spacing Faster travel speeds may be achieved by using higher values of frequency mod ulation See Figure B 8 and B 9p FIGURE B 8 Frequency Modulation 10 Wide weld and ripple spacing slow travel speed FIGURE B 9 IRR RR Frequency Modulation 10 Narrow weld and ripple spacing fast travel speed 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 current continuously swit
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