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IM10038
August, 2010
®
POWER WAVE C300 CE
For use with machines having Code Numbers: 11624
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.
IEC
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines The Above For Diesel Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a.Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mate
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iv iv 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 lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque dʼincendie dû aux étincelles
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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. 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 E
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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. 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 filter
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vii vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to 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 L
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viii viii TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications ...............................................................................................A-1, A-2 Safety Precautions ...............................................................................................................A-3 Location, Lifting .............................................
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ix ix TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ...............................................................................................................D-1 Routine Maintenance ...........................................................................................................D-1 Periodic Maintenance................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER WAVE® C300 CE POWER SOURCE-INPUT VOLTAGE AND CURRENT Input Amperes Model Duty Cycle Input Voltage ± 10% Power Factor @ Idle Power Rated Output 30/28/16/14/11 40% rating 208/230/400*/460/575 K2865-1 300 Watts Max. .95 3 phase 50/60 Hz 100% rating 23/21/12/11/9 (fan on) (* includes 380V to 415V) RATED OUTPUT Process Duty Cycle Volts at Rated Amperes Amperes GMAW 40% 29 300 GMAW-Pulse FCAW 100% 26.5 250 40% 31.2 280 SMAW 100% 29 225 40% 2
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A-2 A-2 INSTALLATION WIRE FEED SPEED RANGE-WIRE SIZE GMAW GMAW GMAW FCAW WFS RANGE MILD STEEL ALUMINUM STAINLESS WIRE SIZES WIRE SIZES WIRE SIZES WIRE SIZES 50 – 700 ipm .025 – .045" .030 – 3/64" .035 – .045" .035 – .052" (1.3 – 17.8 m/min) (0.6 – 1.1mm) (0.8 – 1.2mm) (0.9 – 1.1mm) (0.9 – 1.4mm) WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) OCV (Uo) GMAW GMAW-Pulse 40-300 40-70 VDC average, 100V peak FCAW GTAW-DC 5-300 24 VDC average, 100V peak SMAW 5-280 60 VDC average, 100V peak WIRE SPE
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A-3 A-3 INSTALLATION LIFTING SAFETY PRECAUTIONS Both handles should be used when lifting POWER WAVE® Read this entire installation section before you C300 CE. When using a crane or overhead device a lifting strap start installation. should be connected to both handles. Do not attempt to lift the POWER WAVE® C300 CE with accessories attached to it. WARNING ELECTRIC SHOCK can kill. Do not weld with the POWER WAVE® C300 CE while the machine is suspended by the handles. • Only qualified personne
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A-4 A-4 INSTALLATION INPUT CONNECTION WARNING The POWER WAVE® C300 CE WARNING ON/OFF switch is not intended as a service disconnect for this equip- Only a qualified electrician should ment. Only a qualified electrician connect the input leads to the should connect the input leads to POWER WAVE® C300 CE. the POWER WAVE® C300 CE. Connections should be made in Connections should be made in accordance with accordance with all local and all local and national electrical codes and the con- national
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A-5 A-5 INSTALLATION RECOMMENDED WORK CABLE SEMI-AUTOMATIC WELDING SIZES FOR ARC WELDING POLARITY A work cable is provided with the POWER WAVE® The Fast Mate adapter is permanently wired for C300 CE. This cable is appropriately sized for all of Electrode Positive welding for all GMAW and FCAW the POWER WAVE® C300 CEʼs welding procedures. processes. If the work cable needs to be replaced a similar quality of cable should be used as excessive voltage drops The polarity for GTAW and SMAW proces
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A-6 A-6 INSTALLATION CABLE CONNECTION There is one circular connection on the front of the machine. (See Figure A.2---Table A.1) TABLE A.1 Function Wiring PIN FIGURE A.2 A CANL B CANH C Remote Pot Common 12 pin connector D Remote Pot Wiper for Push pull E Remote Pot +10VDC guns; foot pedal; F ArcLink Peripheral Sense remote controls; G Trigger Hand –amptrols. H Trigger J Power Common K Power + L Motor Negative M Motor Positive CABLE INDUCTANCE AND ITS To minimize inductance always use the app
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A-7 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 WARNING system shielding gas inlet. Tighten the union nuts with a wrench. CYLINDER may explode if 6. Before opening the cylinder valve, turn the regulator damaged. adjusting knob counterclockwise until the adjusting •Keep cylinder upright and spring pressure is released. chained to support. 7. Standing to one side, open the cylinder
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A-8 A-8 INSTALLATION PROCEDURE TO INSTALL DRIVE LOADING SPOOLS OF WIRE ROLLS AND WIRE GUIDES WARNING • Keep hands, hair, clothing and tools away from WARNING rotating equipment. • Do not wear gloves when threading • Turn the input power OFF at the wire or changing wire spool. welding power source before instal- • Only qualified personnel should install, lation or changing drive rolls and/or use or service this equipment. guides. ----------------------------------------------------------------
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A-9 A-9 INSTALLATION FEEDING ELECTRODE AND BRAKE PRESSURE ARM ADJUSTMENT ADJUSTMENT The pressure arm controls the amount of force the drive rolls exert on the wire. Proper adjustment of pressure DRIVE ROLL PRESSURE SETTING arm gives the best welding performance. ELECTRIC SHOCK can kill. • Turn the input power OFF at the weld- Set the pressure arm as follows (See Figure A.6): ing power source before installation or Aluminum wires between 1 and 3 changing drive rolls and/or guides. Cored wire
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A-10 A-10 INSTALLATION TIG WELDING SMAW WELDING (Figure A.7) Most SMAW welding procedures use Electrode When TIG (GTAW) welding with the Power Wave Positive welding. For these applications, connect the C300CE, a torch with an integral gas valve is stick electrode holder to the positive (+) output stud required. and connect the work clamp to the negative (-) output stud. Some SMAW welding procedures use Electrode Negative Polarity. For these applications, connect the stick electrode holder t
