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IM10040
February, 2011
®
POWER WAVE C300
For use with machines having Code Numbers: 11672
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.
OPERA
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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 mat
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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 l’on 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 d’incendie 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 POWER SOuRCE-INPuT VOLTAGE AND CuRRENT Input Amperes Model Duty Cycle Input Voltage ± 10% Power Factor @ Idle Power (1 Phase in paren- Rated Output thesis) 30/28/16/14/11 40% rating 208/230/400*/460/575 (53/48/NA/NA/NA) K2675-2 300 Watts Max. .95 1/3 phase 50/60 Hz 100% rating 23/21/12/11/9 (fan on) (* includes 380V to 415V) (41/37/NA/NA/NA) RATED OuTPuT Process Duty Cycle Volts (RMS) at Rated Amperes Amperes (RMS) GMAW 40% 2
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A-2 A-2 INSTALLATION WIRE FEED SPEED RANGE-WIRE SIzE WFS RANGE GMAW GMAW GMAW FCAW 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 WI
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A-3 A-3 INSTALLATION LIftING SAfEtY PREcAUtIONS Read this Both handles should be used when lifting POWER WAVE® entire installation section before you start installa- C300. When using a crane or overhead device a lifting strap tion. should be connected to both handles. Do not attempt to lift WARNING the POWER WAVE® C300 with accessories attached to it. ELECTRIC ShOCK can kill. Do not weld with the POWER WAVE® C300 while the • Only qualified personnel should machine is suspended by the handles.
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A-4 A-4 INSTALLATION INPuT CONNECTION WARNING The POWER WAVE® C300 ON/OFF WARNING switch is not intended as a service disconnect for this equipment. Only Only a qualified electrician should a qualified electrician should con- connect the input leads to the nect the input leads to the POWER POWER WAVE® C300. Connections WAVE® C300. Connections should should be made in accordance with be made in accordance with all local and national all local and national electrical electrical codes and the co
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A-5 A-5 INSTALLATION RECOMMENDED WORK CAbLE SEMI-AuTOMATIC WELDING SIzES FOR ARC WELDING POLARITY A 15 ft. work cable is provided with the POWER Most GMAW welding procedures use Electrode WAVE® C300. This cable is appropriately sized for all Positive welding. For these applications, connect the of the POWER WAVE® C300’s welding procedures. If wire drive’s connection block to the positive (+) output the work cable needs to be replaced a similar quality stud and connect the work lead to the neg
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A-6 A-6 INSTALLATION 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) TAbLE A.1 Function PIN Wiring FIGuRE A.2 22 11 33 44 1 44 Supply Voltage for Dual Procedure 4-pin trigger con- 2 22 Dual Procedure Input nector for push- 3 Trigger Input 33 only guns. 4 Supply Voltage for Trigger 11 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 A
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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 WARNING the flow regulator. Attach the other end to the welding system shielding gas inlet. Tighten the union nuts with a wrench. CYLINDER may explode if damaged. 6. Before opening the cylinder valve, turn the regulator • Keep cylinder upright and adjusting knob counterclockwise until the adjusting chained to support. spring pressure is released. • Keep cylinder away from areas where
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A-8 A-8 INSTALLATION LOADING SPOOLS OF WIRE WARNING • Keep hands, hair, clothing and tools away from rotating equipment. • Do not wear gloves when threading wire or changing wire spool. • Only qualified personnel should install, use or service this equipment. ------------------------------------------------------------------------ Loading 10 to 15 lb. (4.5 – 6.8kg) Spools. A K468 spindle adapter permits 8” (203mm) O.D. spools to be mounted on 2” (51mm) O.D. spindles. 1. Squeeze the release ba
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A-9 A-9 INSTALLATION WIRE DRIVE CONFIGuRATION 8. Connect the shielding gas hose to the new gun bushing, if required. (See Figure A.4) 9. Rotate the gun bushing until the thumb screw hole Changing the Gun Receiver bushing aligns with the thumb screw hole in the feed plate. WARNING Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned. 10. Tighten the socket head cap screw. ELECTRIC ShOCK can kill. 11. Insert the welding gun into the gun bushing and • T
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A-10 A-10 INSTALLATION 1. Press end of gun against a solid object that is elec- GuN uSED trically isolated from the welder output and press the gun trigger for several seconds. The Magnum 350PRO is the recommended gun for the POWER WAVE® C300. Refer to the Magnum 2. If the wire "birdnests", jams, or breaks at the drive 350PRO’s operators manual for installation instruc- roll, the drive roll pressure is too great. Back the tions. pressure setting out turn, run new wire through gun, and rep
