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Lincoln Electric POWER WAVE 300C User Manual

Lincoln Electric POWER WAVE 300C
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Operator’s Manual
POWER WAVE
®
300C
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM10591 | Issue D ate Oct - 20
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12942, 12943, 12944, 12945
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
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Lincoln Electric POWER WAVE 300C Specifications

General IconGeneral
Input Phase3
Input Frequency50/60 Hz
Output Current Range5-300A
Output Voltage Range10 - 40 V
Duty Cycle60%
ProcessesMIG, TIG, Stick
Wire Feed Speed50-1000 ipm
Wire Diameter Range0.023 - .045 in

Summary

Safety First

Keep Your Head Out of the Fumes

Advice on fume avoidance and ventilation to maintain a safe breathing zone.

Wear Correct Eye, Ear & Body Protection

Guidance on personal protective equipment for welding to prevent injury.

Special Situations and Precautions

Warnings for specific hazardous situations and additional safety steps.

Section A: Warnings

California Proposition 65 Warnings

Warnings regarding chemicals known to cause cancer or birth defects.

Arc Welding Hazards

General hazards of arc welding and precautions for specific individuals.

Engine Powered Equipment Safety

Safety guidelines for operating engine-powered equipment.

Electric and Magnetic Fields

Potential dangers and precautions related to EMF generated by welding.

Electric Shock Can Kill

Precautions to prevent electrical shock hazards during welding.

Arc Rays Can Burn

Safety measures to protect against burns from arc rays.

Fumes and Gases Can Be Dangerous

Warnings about hazardous fumes and gases produced during welding.

Fire and Explosion Hazards

Risks associated with welding sparks and flammable materials.

Cylinder Safety

Precautions for handling compressed gas cylinders to prevent explosions.

Electrically Powered Equipment Safety

Safety guidelines for electrically powered welding equipment.

Electromagnetic Compatibility (EMC)

Conformance and Introduction

Details on EMC compliance and general information about emissions.

Installation and Use Considerations

User responsibilities for installing and using equipment to manage interference.

Area Assessment for Interference

Evaluating the surrounding area for potential electromagnetic problems.

Methods of Reducing Emissions

Techniques to minimize electromagnetic emissions from the welding equipment.

Equipment Maintenance and Cables

Proper maintenance, cable management, and bonding for EMC.

Installation and Setup

Technical Specifications

Detailed input voltage, current, and output ratings for the machine.

Wire Feed Speed and Size Specifications

Details on wire feed speed ranges and compatible wire sizes.

Welding Process and Output Ranges

Information on supported welding processes and their output parameters.

Physical Dimensions and Temperature Ranges

Specifications for machine size, weight, and operating/storage temperatures.

Installation Safety Precautions

Essential safety guidelines to follow during equipment installation.

Selecting a Suitable Location

Guidance on choosing an appropriate and safe operating location for the machine.

Machine Setup and Connections

Instructions for stacking, tilting, input/ground connections, and grounding.

High Frequency Protection

Information regarding electromagnetic compatibility and RF interference.

Input Connection and Power Cords

Details on connecting input power, fuses, wire sizes, and replacing power cords.

Input Voltage Selection

Information on how the machine automatically adjusts to different input voltages.

Work Cable Sizes and Voltage Sensing

Recommendations for work cable sizes and explanation of voltage sensing.

Semi-Automatic Welding Polarity

Guidelines for setting electrode polarity in semi-automatic welding.

Cable Connections and Inductance

Details on connecting cables and understanding inductance effects on welding.

Shielding Gas Connection

Step-by-step instructions for connecting the shielding gas supply.

Loading Wire Spools

Instructions for loading 10-15 lb and 16-44 lb wire spools.

Wire Drive Configuration and Component Installation

Steps for changing gun bushings and installing drive rolls/guides.

Gun Usage and Electrode Feeding

Information on recommended guns and adjusting electrode feeding.

Drive Roll Pressure and Arm Adjustment

How to set drive roll pressure and adjust the pressure arm for optimal feed.

TIG and SMAW Welding Setup

Connection and polarity details for TIG and SMAW welding processes.

Core Operation Procedures

Safety Precautions for Operation

Key safety guidelines to follow before and during machine operation.

Graphic Symbols Overview

Explanation of graphic symbols used on the machine and in the manual.

Power-Up Sequence and Duty Cycle

Understanding the machine's startup process and duty cycle ratings.

Product Description and Capabilities

Overview of the machine's features, capabilities, and models.

Recommended Processes and Equipment

Guidance on suitable welding processes and associated equipment.

Process and Equipment Limitations

Information on supported processes and limitations of the equipment.

Design Features of the Power Wave 300C

Detailed overview of the machine's standard design features and technologies.

Standard Model Front Controls Overview

Identification and function of controls on the front panel of the standard model.

Advanced Model Front Controls Overview

Identification and function of controls on the front panel of the advanced model.

Machine Back Panel Controls and Connections

Description of controls and connectors located on the back of the machine.

Internal Machine Components and Controls

Identification of internal components and controls within the machine.

Advanced Welding Operations

General Welding Procedures and Responsibilities

Guidance on weld procedures, material selection, and user responsibility.

Welding Mode Definitions

Explanation of non-synergic and synergic welding modes.

Basic Welding Control Parameters

Overview of controls like Weld Mode, WFS, Amps, Volts, Trim, and Ultimarc.

User Interface Layout and Navigation

Explanation of the user interface elements and navigation controls.

Simplified Home Screen Navigation

Understanding the simplified home screen layout for FCAW welding.

SMAW Home Screen Navigation (Advanced)

Navigating the SMAW home screen and understanding its controls.

GTAW Home Screen Navigation (Advanced)

Navigating the GTAW home screen and understanding its controls.

GTAW Start and End Settings

Configuring start and end parameters for GTAW welding.

FCAW Home Screen Navigation (Advanced)

Navigating the FCAW home screen and understanding its controls.

GMAW Home Screen Navigation (Advanced)

Navigating the GMAW home screen and understanding its controls.

FCAW/GMAW Start and End Settings

Configuring start and end parameters for FCAW/GMAW welding.

System Menu and Settings

USB Memory Media Management

Managing software updates and data via USB memory media.

Memory Management

Viewing and managing saved welding memories.

Language and Display Unit Settings

Configuring language preferences and display units (metric/imperial).

Advanced System Settings Configuration

Adjusting software versions, weld feedback persistence, and home screen layout.

Advanced Process Settings Menu

Accessing and adjusting advanced process settings like Arc Force and Hot Start.

Pinch Setting Indicator and Usage

Understanding the pinch setting indicator and its effect on arc characteristics.

Welding Screen Overview

Understanding the welding screen display for current, voltage, and active settings.

Back and Home Button Functions

Navigating between screens using the back and home buttons.

Memory Operation and Saving

Saving and accessing welding memories for different processes.

User Interface Programming and Wave Control

Performing Software Updates

Steps for updating the user interface software via USB.

Wave Control Parameters Explained

Details on Wave Control parameters like Arc Force, Pinch, Ultimarc, AC Frequency, Pulse, etc.

Trigger Operation Modes

2-Step Trigger Operation

Explanation of the basic 2-step trigger sequence for welding.

2-Step Trigger with Start/Burnback Control

Utilizing start and burnback functions for improved arc start and end.

2-Step Trigger with Start/Crater/Burnback Control

Customizing start, crater, and burnback parameters for optimal welds.

4-Step Trigger Operation

4-Step Trigger Interlock Configuration

Using the 4-step trigger as an interlock for increased operator comfort.

4-Step Trigger with Manual Start/Crater Control

Manual control of start, crater, and burnback for enhanced welding flexibility.

Cold Feed and Gas Purge Operation

Cold Feed and Gas Purge Switch Functionality

How to use the combined switch for cold feeding and gas purging.

Options and Accessories

Gas Bottle and Cooling System Accessories

Kits for dual gas bottles, water cooler adapters, and the water cooler itself.

Auxiliary Kits, Guns, and Connectors

Accessories like auxiliary kits, welding guns, and connectors for compatibility.

Remote Controls and TIG Torches

Options for remote output control, arc start switches, and TIG torches.

Spindle Adapters and Related Parts

Adapters for mounting small spools and coils, and related accessories.

Maintenance and Calibration

Maintenance Safety Precautions

Essential safety measures before performing maintenance or servicing.

Routine and Periodic Maintenance

Guidelines for regular cleaning and annual calibration checks.

Calibration Specification and Procedure

Information on machine calibration accuracy and using the Diagnostics Utility.

Troubleshooting Guide Usage

Understanding the Troubleshooting Process

How to use the guide by identifying symptoms, causes, and actions.

Troubleshooting Safety Warnings

Critical safety warnings to observe when troubleshooting or performing repairs.

Troubleshooting with Status LEDs and Error Codes

Status LED Indicators and Meanings

Interpretation of status LED lights for normal operation and error conditions.

Error Code Interpretation

How to interpret error codes indicated by status lights or beep codes.

Main Control Board and Wire Drive Error Codes

List of common error codes for the main control board and wire drive module.

Input Control Board Error Codes

List of common error codes related to the input control board.

Basic Machine Troubleshooting

Input Fuse Issues

Diagnosing and resolving problems with blowing input fuses.

Power Up and Output Problems

Troubleshooting issues related to the machine not powering up or producing output.

Thermal LED and Real-Time Clock Issues

Addressing issues when the thermal LED is on or the real-time clock fails.

Weld Performance Degradation

Diagnosing causes for general degradation in weld performance.

Weld and Arc Quality Troubleshooting

Wire Burnback and Output Shutdown Issues

Resolving wire burnback at weld end and machine output shutdown during welding.

Full Output and Arc Quality Problems

Addressing issues with producing full output and erratic arc behavior.

Ethernet Connectivity Troubleshooting

Ethernet Connection and IP Address Issues

Resolving problems with connecting to Ethernet or IP address configuration.

Connection Drops and Cable Location

Addressing intermittent connection drops and cable placement issues.

Customer Assistance Policy

Lincoln Electric's Business and Support Policy

Information on Lincoln Electric's commitment to quality and customer support.

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