Lincoln Electric IM10040 User Manual

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IM10040-A

February 2013

For use with machines having Code Numbers:

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.

11672, 11958

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 USA TEL: [phone]

For Service in the USA and Canada: Call 1.888.935.3877 For Service outside the USA: Email [e-mail]

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

FAX: [phone] WEB SITE: lincolnelectric.com

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot 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 devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

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SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform 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 suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum­stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

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SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current 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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

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 Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.

vv

Note: The welding circuit may or may not be earthed for safety reasons according to national codes.

Changing the earthing arrangements should only be authorized by a person who is compe­tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment 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 additional protection measures;

h) the time of day that welding or other activities are to be carried out.

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 recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip­ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip­ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

vivi

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec­tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob­lems of interference. Screening of the entire welding installation may be considered for special

applications

1.

_________________________

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”

Thank You

viivii

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs 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 advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

Your Product”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications ...............................................................................................A-1, A-2

Safety Precautions ...............................................................................................................A-3

Location, Lifting .............................................................................................................A-3

Stacking ........................................................................................................................A-3

Tilting.............................................................................................................................A-3

Input and Ground Connections .....................................................................................A-3

Machine Grounding.......................................................................................................A-3

High Frequency Protection............................................................................................A-3

Input Connection ..................................................................................................................A-4

Input Fuse and Supply Wire..........................................................................................A-4

Input Voltage Selection .................................................................................................A-4

Power Cord Replacement .............................................................................................A-4

Connection Diagram .....................................................................................................A-5

Recommended Work Cable Sizes ................................................................................A-5

Remote Sense Lead Specifications, Semi Automatic Welding .....................................A-5

Polarity ..........................................................................................................................A-5

Cable Connections ...............................................................................................................A-6

Cable Inductance and its Effects on Welding................................................................A-6

Shielding Gas Connections ..................................................................................................A-7

Loading Spool Wire ..............................................................................................................A-8

Wire Drive Configuration ......................................................................................................A-9

Procedure to Install Drive Rolls and Wire Guides .........................................................A-9

Gun Used ...........................................................................................................................A-10

Feeding Electrode and Brake Adjustment...................................................................A-10

Drive Roll Pressure Setting .........................................................................................A-10

TIG Welding .......................................................................................................................A-11

SMAW Welding ...........................................................................................................A-11

________________________________________________________________________________

viiiviii

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Graphic Symbols...........................................................................................................B-1

Power-Up Sequence .....................................................................................................B-1

Duty Cycle.....................................................................................................................B-1

Product Description ..............................................................................................................B-2

Recommended Processes and Equipment ..........................................................................B-2

Equipment Limitations ..........................................................................................................B-3

Common Equipment Packages.....................................................................................B-3

Design Features............................................................................................................B-3

Case Front Controls .............................................................................................................B-4

Case Back Controls..............................................................................................................B-5

Internal Controls ...................................................................................................................B-6

Making a Weld with Waveform Technology Power Sources ................................B-7 thru B-16

Procedure/Memory Panel Operation ..................................................................B-17 thru B-19

2 Step - 4 Step Trigger Operation and Graphics ................................................B-20 thru B-25

Cold Feed/Gas Purge Switch .............................................................................................B-26

Spool Gun Operation..........................................................................................B-26 thru B-27

Set-Up Feature Menu ........................................................................................B-28 thru B-35

________________________________________________________________________________

Accessories.....................................................................................................Section C

General Options / Accessories..............................................................................C-1

Stick Operations ....................................................................................................C-1

TIG Options / Accessories.....................................................................................C-1

Wire Feed Options ...............................................................................................

C-2 thru C-3

________________________________________________________________________

TABLE OF CONTENTS

Page

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

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

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

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

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

________________________________________________________________________________

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

________________________________________________________________________________

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

________________________________________________________________________

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

_______________________________________________________________________

________

ixix

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE®C300

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

K2675-2
K3288-1

Process

Duty Cycle

40% rating

100% rating

Duty Cycle

Input Voltage ± 10%

208/230/400*/460/575

1/3 phase 50/60 Hz

(* includes 380V to 415V)

RATED OUTPUT

Volts (RMS) at Rated Amperes

Input Amperes

(1 Phase in paren-

thesis)

30/28/16/14/11

(53/48/NA/NA/NA)

23/21/12/11/9

(41/37/NA/NA/NA)

Idle Power

300 Watts Max.

(fan on)

Amperes (RMS)

A-1

Power Factor @

Rated Output

.95

GMAW

GMAW-Pulse

FCAW

SMAW

GTAW-DC

FREQUENCY

40%

100%

40%

100%

40%

100%

INPUT

VOLTAGE /

PHASE/

208/1/50/60
208/3/50/60
230/1/50/60
230/3/50/60
400/3/50/60
460/3/50/60
575/3/50/60

29

26.5

31.2

29

22

20

RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT AMPERE

RATING ON

NAMEPLATE

53
30
48
28
16
14
11

CORD SIZES

AWG SIZES (mm2)

6 (16)
8 (10)
6 (16)
8 (10)

12 (4)
14 (2.5)
14 (2.5)

3

300

250

280

225

300

250

1

TIME DELAY FUSE

OR BREAKER

2

SIZE

(AMPS)

70
40
70
40
25
20
15

1

Wire and Fuse Sizes based upon the U.S. National Electric Code and maximum output for 40°C (104°) ambient.

2

Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers that have a delay in tripping action that decreases as the

magnitude of current increases.

3

Type SO cord or similar in 30°C ambient.

POWER WAVE®C300

A-2

WIRE FEED SPEED RANGE-WIRE SIZE

WFS RANGE

INSTALLATION

GMAW

MILD STEEL

WIRE SIZES

GMAW

ALUMINUM

WIRE SIZES

GMAW

STAINLESS

WIRE SIZES

A-2

FCAW

WIRE SIZES

MODEL

K2675-2

50 – 700 ipm

(1.3 – 17.8 m/min)

PROCESS

GMAW

GMAW-Pulse

FCAW

GTAW-DC

SMAW

Wire Speed

HEIGHT

18.8in (478mm)

.025 – .045"

(0.6 – 1.1mm)

.030 – 3/64"

(0.8 – 1.2mm)

WELDING PROCESS

OUTPUT RANGE (AMPERES)

40 - 300

5 – 300
5 – 280

WIRE SPEED RANGE

50 – 700 IPM (1.27 – 17.8 m/minute)

PHYSICAL DIMENSIONS

WIDTH

14.00in (356mm)

TEMPERATURE RANGES

.035 – .045"

(0.9 – 1.1mm)

OCV (Uo)

40-70 VDC average, 100V peak

24 VDC average, 100V peak
60 VDC average, 100V peak

DEPTH

27.4in (697mm)

.035 – .052"

(0.9 – 1.4mm)

WEIGHT

100.0lbs (47.6kg)*

OPERATING TEMPERATURE RANGE

Environmentally Hardened: -4°F to 104°F (-20C to 40C)

IP23 155º(F) Insulation Class

* Weight does not include input cord.

Thermal tests have been performed at ambient tem­perature. The duty cycle (duty factor) at 40°C has
been determined by simulation.

STORAGE TEMPERATURE RANGE

Environmentally Hardened: -40°F to 185°F (-40C to 85C)

POWER WAVE®C300

A-3

INSTALLATION

A-3

SAFETY PRECAUTIONS Read this

entire installation section before you start installa­tion.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

• Turn the input power OFF at the

disconnect switch or fuse box before working on
this equipment. Turn off the input power to any
other equipment connected to the welding system
at the disconnect switch or fuse box before work­ing on the equipment.

• Do not touch electrically hot parts.

• Always connect the POWER WAVE
grounding lug (located inside the reconnect
input access door) to a proper safety (Earth)
ground.

------------------------------------------------------------------------

®

C300

LIFTING

Both handles should be used when lifting POWER WAVE
C300. When using a crane or overhead device a lifting strap
should be connected to both handles. Do not attempt to lift
the POWER WAVE

Do not weld with the POWER WAVE
machine is suspended by the handles.

STACKING

The POWER WAVE®C300 cannot be stacked.

TILTING

SELECT SUITABLE LOCATION

The POWER WAVE®C300 will operate in harsh environ­ments. Even so, it is important that simple preventative
measures are followed in order to assure long life and reli­able operation.

• The machine must be located where there is free circula­tion of clean air such that air movement in the back, out
the sides and bottom will not be restricted.

Place the machine directly on a secure, level surface or on
a recommended undercarriage. The machine may topple
over if this procedure is not followed.

INPUT AND GROUND CONNECTIONS

Only a qualified electrician should connect the POWER
WAVE®C300. Installation should be made in accordance
with the appropriate National Electrical Code, all local
codes and the information in this manual.

MACHINE GROUNDING

• Dirt and dust that can be drawn into the machine should
be kept to a minimum. The use of air filters on the air
intake is not recommended because normal air flow may
be restricted. Failure to observe these precautions can
result in excessive operating temperatures and nuisance
shutdown.

The frame of the welder must be grounded. A ground ter­minal marked with a ground symbol is located next to the
input power connection block.

See your local and national electrical codes for proper
grounding methods.

HIGH FREQUENCY PROTECTION

• Keep machine dry. Shelter from rain and snow. Do not
place on wet ground or in puddles.

• Do not mount the POWER WAVE
bustible surfaces. Where there is a 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 the equipment on all sides.

®

C300 over com-

The EMC classification of the POWER WAVE®C300 is
Industrial, Scientific and Medical (ISM) group 2, class A.
The POWER WAVE®C300 is for industrial use only. (See
Electromagnetic Compatibility EMC Safety Section).

Locate the POWER WAVE
trolled machinery. The normal operation of the POWER
WAVE
trolled equipment, which may result in bodily injury or dam­age to the equipment.

®

®

C300 with accessories attached to it.

®

C300 while the

WARNING

• Lift only with equipment of adequate
lifting capacity.

• Be sure machine is stable when lifting.

• Do not operate machine while suspend­ed when lifting.

FALLING

EQUIPMENT can

cause injury.

-----------------------------------------------------------------------------------------------

®

C300 away from radio con-

®

C300 may adversely affect the operation of RF con-

POWER WAVE®C300

A-4

INSTALLATION

INPUT CONNECTION

WARNING

Only a qualified electrician should
connect the input leads to the
POWER WAVE®C300. Connections
should be made in accordance with

all local and national electrical
codes and the connection diagram located on the
inside of the reconnect access door of the
machine. Failure to do so may result in bodily
injury or death.

A-4

WARNING

The POWER WAVE®C300 ON/OFF
switch is not intended as a service
disconnect for this equipment. Only
a qualified electrician should con­nect the input leads to the POWER

WAVE
be made in accordance with all local and national
electrical codes and the connection diagram locat­ed on the inside of the reconnect access door of
the machine. Failure to do so may result in bodily
injury or death.

®

C300. Connections should

------------------------------------------------------------------------

A 15 ft. power cord is provided and wired into the
machine. Follow the power cord connection instruc­tions.

For Single Phase Input

Connect green lead to ground per National Electrical
Code.

Connect black and white leads to power.

Wrap red lead with tape to provide 600V insulation.

For Three Phase Input

Connect green lead to ground per National Electric
Code.

Connect black, red and white leads to power.

INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS

Refer to Specification Section for recommended fuse,
wire sizes and type of the copper wires. Fuse the
input circuit with the recommended super lag fuse or
delay type breakers (also called "inverse time" or
"thermal/magnetic" circuit breakers). Choose input
and grounding wire size according to local or national
electrical codes. Using input wire sizes, fuses or cir­cuit breakers smaller than recommended may result in
"nuisance" shut-offs from welder inrush currents, even
if the machine is not being used at high currents.

INPUT VOLTAGE SELECTION

The POWER WAVE®C300 automatically adjusts to
work with different input voltages. No reconnect
switches settings are required.

------------------------------------------------------------------------

POWER CORD REPLACEMENT

WARNING

Only a qualified electrician should
connect the input leads to the
POWER WAVE
should be made in accordance with
all local and national electrical

codes and the connection diagram
located on the inside of the reconnect access
door of the machine. Failure to do so may result
in bodily injury or death.

------------------------------------------------------------------------

If the input power cord is damaged or needs to be
replaced an input power connection block is located in
the access panel under the wire spool.

ALWAYS CONNECT THE POWERWAVE GROUND­ING LUG (LOCATED INSIDE THE ACCESS PANEL)
TO A PROPER SAFETY (EARTH) GROUND.

FIGURE A.1

ACCESS PANEL

®

C300. Connections

BLACK

RED

GREEEN

GROUND LUG

WHITE

INPUT CORD

POWER WAVE®C300

A-5

INSTALLATION

A-5

RECOMMENDED WORK CABLE
SIZES FOR ARC WELDING

A 15 ft. work cable is provided with the POWER
WAVE
of the POWER WAVE®C300ʼs welding procedures. If
the work cable needs to be replaced a similar quality
of cable should be used as excessive voltage drops
caused by undersized welding cables can result in
unsatisfactory welding performance. Always use the
largest work cables that is practical, and be sure all
connections are clean and tight.

Note: Excessive heat in the weld circuit indicates
undersized cables and/or bad connections.

®

C300. This cable is appropriately sized for all

REMOTE SENSE LEAD SPECIFICA­TIONS

Since the POWER WAVE®C300 has the ability to be
in close proximity to the welding arc, the POWER
WAVE®C300 does not require the use of remote
sense leads.

SEMI-AUTOMATIC WELDING
POLARITY

Most GMAW welding procedures use Electrode
Positive welding. For these applications, connect the
wire driveʼs connection block to the positive (+) output
stud and connect the work lead to the negative (-) out­put stud.

Some FCAW-SS does use Electrode Negative
Polarity. For these applications, connect the wire
driveʼs connection block to the negative (-) output stud
and connect the work lead to the positive (+) output
stud.

POWER WAVE®C300

A-6

3

4

2

1

INSTALLATION

CABLE CONNECTIONS

There are two circulars connector in the wire drive compart­ment. (See 4-pin and 12-pin---Figure A.2---Table A.1)

TABLE A.1

FIGURE A.2

Function

4-pin trigger con-

nector for push-

only guns.

PIN

1

Supply Voltage for Dual Procedure

2
3
4

A-6

Wiring

Dual Procedure Input

Trigger Input

Supply Voltage for Trigger

12 pin connector

for Push pull

guns; foot pedal;

remote controls;

Hand –amptrols.

CABLE INDUCTANCE AND ITS
EFFECTS ON WELDING

Whenever possible always weld in a direction
away from the work (ground) connection.

Excessive cable inductance will cause the welding
performance to degrade. There are several factors
that contribute to the overall inductance of the cabling
system including cable size, and loop area. The loop
area is defined by the separation distance between
the electrode and work cables, and the overall welding
loop length. The welding loop length is defined as the
total of length of the electrode cable (A) + work cable
(B) + work path (C) (see Figure A.3).

A
B
C
D
E
F
G
H

J
K
L

M

Remote Pot Common

Remote Pot +10VDC

ArcLink Peripheral Sense

To minimize inductance always use the appropriate
size cables, and whenever possible, run the electrode
and work cables in close proximity to one another to
minimize the loop area. Since the most significant fac­tor in cable inductance is the welding loop length,
avoid excessive lengths and do not coil excess cable.
For long work piece lengths, a sliding ground should
be considered to keep the total welding loop length as
short as possible.

For additional Safety information regarding the
electrode and work cable set-up, See the standard
“SAFETY INFORMATION” located in the front of
this Instruction Manual.

CANL

CANH

Remote Pot Wiper

Trigger
Trigger

Power Common

Power +

Motor Negative

Motor Positive

FIGURE A.3

A

C

WORK

B

POWER WAVE®C300

A-7

INSTALLATION

SHIELDING GAS CONNECTION

WARNING

CYLINDER may explode if

damaged.

• Keep cylinder upright and
chained to support.

A-7

5. Attach one end of the inlet hose to the outlet fitting of
the flow regulator. Attach the other end to the welding
system shielding gas inlet. Tighten the union nuts
with a wrench.

6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.

• Keep cylinder away from areas where it may be
damaged.

• Never lift welder with cylinder attached.

• Never allow welding electrode to touch cylinder.

• Keep cylinder away from welding or other live
electrical circuits.

• BUILD UP OF SHIELDING GAS MAY
HARM HEALTH OR KILL.

• 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.

------------------------------------------------------------------------

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 hose from the gas cylinder flow valve
outlet to the 5/8-18 female inert gas fitting on the back

®

panel of the Power Wave

M

AXIMUM INLET PRESSURE IS 100 PSI. (6.9 BAR.)

Install the shielding gas supply as follows:

C300.

7. 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.

8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making a weld

1. Secure the cylinder to prevent it from falling.

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 suppli-

er of this condition. Oil or grease in the presence of
high pressure oxygen is explosive.

3. 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.

4. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench.

Note: if connecting to 100% CO
ulator adapter between regulator and cylinder valve.
If adapter is equipped with a plastic washer, be sure it

is seated for connection to the CO2cylinder.

2

cylinder, insert reg-

POWER WAVE®C300

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-8

A K468 spindle adapter permits 8”
spools to be mounted on 2” (51mm) O.D. spindles.

1. Squeeze the release bar on the retaining collar and

remove it from the spindle.

2. Place the spindle adapter on the spindle, aligning

the spindle brake pin with the hole in the adapter.

3. Place the spool on the spindle and align the

adapter brake tab with one of the holes in the back
side of the spool. An indicator mark 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 snaps out and that the retaining collar
fully engages the groove on the spindle.

Loading 16 to 44 lb. (7.3 – 20kg) Spools

1. Squeeze the release bar on the retaining collar and

remove it from the spindle.

(203mm) O.D.

2. Place the spool on the spindle, aligning the spindle

brake pin with one of the holes in the back side of
the spool. An indicator mark on the end of the spin­dle shows the orientation of the brake holding pin.
Be certain the wire feeds off of the spool in the
proper direction.

3. Re-install the retaining collar. Make sure that the

release bar snaps out and that the retaining collar
fully engages the groove on the spindle

POWER WAVE®C300

A-9

INSTALLATION

A-9

WIRE DRIVE CONFIGURATION

(See Figure A.4)

Changing the Gun Receiver Bushing

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the
welding power source before instal­lation or changing drive rolls and/or
guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode
and drive mechanism are "hot" to work and
ground and could remain energized several sec­onds after the gun trigger is released.

• Do not operate with covers, panels or guards
removed or open.

• Only qualified personnel should perform mainte­nance work.

------------------------------------------------------------------------

Tools required:

• 1/4" hex key wrench.
Some gun bushings do not require the use of

Note:

the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.

Important: Do not attempt to completely
remove the socket head cap screw.

6. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the pre­cision fit, light tapping may be required to remove
the gun bushing.

7. Disconnect the shielding gas hose from the gun
bushing, if required.

8. Connect the shielding gas hose to the new gun
bushing, if required.

9. Rotate the gun bushing until the thumb screw hole
aligns with the 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 the gun bushing and
tighten the thumb screw.

PROCEDURE TO INSTALL DRIVE
ROLLS AND WIRE GUIDES

WARNING

• Turn the input power OFF at the
welding power source before instal­lation or changing drive rolls and/or
guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground
and could remain energized several seconds
after the gun trigger is released.

• Do not operate with covers, panels or guards
removed or open.

• Only qualified personnel should perform mainte­nance work.

------------------------------------------------------------------------

1. Turn power off at the welding power source.

2. Release the idle roll pressure arm.

Remove the outer wire guide by turning the knurled

3.

thumbscrews counter-clockwise to unscrew them
from the feed plate.

4. Rotate the triangular lock and remove the drive

rolls.

FIGURE A.5

GUN RECEIVER BUSHING

CONNECTOR BLOCK

THUMB SCREW

SOCKET HEAD
CAP SCREW

OUTER WIRE GUIDE

LOOSEN TIGHTEN

5. Remove the inner wire guide.

6. Insert the new inner wire guide, groove side out,

over the two locating pins in the feed plate.

7. Install a drive roll on each hub assembly secure

with the triangular lock.

8. Install the outer wire guide by aligning it with the

pins and tightening the knurled thumbscrews.

9. Close the idle arm and engage the idle roll pressure

arm. Adjust the pressure appropriately

POWER WAVE®C300

A-10

INSTALLATION

A-10

GUN USED

The Magnum®350PRO is the recommended gun for
the POWER WAVE
350PROʼs operators manual for installation instruc­tions.

®

C300. Refer to the Magnum

FEEDING ELECTRODE AND BRAKE
ADJUSTMENT

1. Turn the Reel or spool until the free end of the
electrode is accessible.

2. While tightly holding the electrode, cut off the bent
end and straighten the first 6" (150 mm). Cut off
the first 1" (25 mm). (If the electrode is not properly
straightened, it may not feed or may jam causing a
"birdnest".)

3. Insert the free end through the incoming guide
tube.

4. Press the Cold Inch key and push the electrode
into the drive roll.

5. Feed the electrode through the gun.

1. Press end of gun against a solid object that is elec­trically isolated from the welder output and press
the gun trigger for several seconds.

2. If the wire "birdnests", jams, or breaks at the drive
roll, the drive roll pressure is too great. Back the
pressure setting out turn, run new wire through gun,
and repeat above steps.

3. If the only result is drive roll slippage, disengage the
gun, pull the gun cable forward about 6" (150 mm).
There should be a slight waviness in the exposed
wire. If there is no waviness, the pressure is too
low. Increase the pressure setting turn, reconnect
the gun, tighten locking clamp and repeat the above
steps.

PRESSURE ARM ADJUSTMENT

The pressure arm controls the amount of force the drive
rolls exert on the wire. Proper adjustment of pressure
arm gives the best welding performance.

Set the pressure arm as follows: (See Figure A.6)

Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6

6. Adjust the brake tension with the thumbscrew on
the spindle hub, until the reel turns freely but with
little or no overrun when wire feeding is stopped.
Do not over tighten.

DRIVE ROLL PRESSURE SETTING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the weld­ing power source before installation or
changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When feeding with the gun trigger, unless
“COLD FEED” trigger mode is selected, the elec­trode and drive mechanism are always “HOT” to
work and ground and could remain “HOT” sev­eral seconds after the gun trigger is released.

• Do not operate with covers, panels or guards
removed or open

• Only qualified personnel should perform mainte­nance work.

------------------------------------------------------------------------

The POWER WAVE
sure varies with type of wire, surface condition, lubri­cation, and hardness. Too much pressure could cause
birdnesting”, but too little pressure could cause wire
feed slippage with load and/or acceleration. The opti­mum drive roll setting can be determined as follows:

®

C300ʼs optimum drive roll pres-

Cored wires

FLUX CORE
ARC WELDING

FIGURE A.6

1
3

5

2
4
6

ALUMINUM

GAS METAL
ARC WELDING

Aluminum wires

Steel, Stainless wires

POWER WAVE®C300

A-11

INSTALLATION

A-11

TIG WELDING

(Figure A.7)

Tig uses Electrode Negative Polarity so for this appli­cation, connect the Tig torch to the negative (-) output
stud and connect the work clamp to the positive (+)
output stud. The TIG torch gas connection should be
connected to the POWER WAVE
supply connection. If required a foot amptrol can be
connected to the remote control receptacle.

®

C300ʼs internal gas

FIGURE A.7

SMAW WELDING

Most SMAW welding procedures use Electrode
Positive welding. For these applications, connect the
stick electrode holder to the positive (+) output stud
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 to the negative (-) output stud
and connect the work clamp to the positive (+) output
stud.

12 PIN CONNECTOR

GAS SUPPLY
CONNECTION

NEGATIVE
STUD (-)

WORK CLAMP

WORK PIECE

POWER CABLE

TO POSITIVE
STUD (+)

TIG TORCH

4 PIN GUN TRIGGER
CONNECTOR

POSITIVE
STUD (+)

TO NEGATIVE
STUD (-)

TO GAS SUPPLY
CONNECTION

GAS HOSE

TO REMOTE CONTROL
RECEPTACLE

FOOT AMPTROL
(OPTIONAL)

POWER WAVE®C300

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.

WARNING

• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED fea­ture, when feeding with gun trig­ger, the electrode and drive
mechanism are always electri­cally energized and could
remain energized several sec­onds after the welding ceases.

• Do not touch electrically live part or electrode
with skin or wet clothing.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

• Do not operate with covers, panels or guards
removed or open.

---------------------------------------------------------------------

• FUMES AND GASSES can be
dangerous.

• Keep your head out of fumes.

Use ventilation or exhaust to

•
remove fumes from breathing
zone.

---------------------------------------------------------------------

• WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

WARNING OR
CAUTION

DANGEROUS
VOLTAGE

POSITIVE OUTPUT

NEGATIVE OUTPUT

HIGH TEMPERATURE

STATUS

PROTECTIVE
GROUND

---------------------------------------------------------------------

ARC RAYS can burn.

•

Wear eye, ear and body protec­tion.

---------------------------------------------------------------------

SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE
UAL.

---------------------------------------------------------------------

FRONT OF THIS OPERATING MAN-

POWER-UP SEQUENCE

When the POWER WAVE®C300 is powered it can
take as long as 30 seconds for the machine to be
ready to weld. During this time period the user inter-

face will not be active.

DUTY CYCLE

The POWER WAVE®C300 is rated at 250 amps at

26.5 volts with a 100% duty cycle. It is further rated to
provide 275 amps at 27.8 volts with a 60% duty cycle
and 300 amps at 29 volts with a 40% duty cycle. The
duty cycle is based on a ten-minute period. A 60%
duty cycle represents 4 minutes of welding and 6 min-

utes of idling in a ten-minute period.

POWER WAVE®C300

B-2

OPERATION

PRODUCT DESCRIPTION

The Power Wave®C300 is a high performance multi­process machine with GMAW, FCAW, SMAW, DC
TIG, and pulse capability. It will offer a premier weld­ing performance solution for specific areas such as
aluminum, stainless, nickel where size and weight are
an issue.

The Power Wave

• Power - 300A @ 40%, 275A @ 60%, 250A @
100%.

• Multi Input Voltage with no reconnect - 200-600V,
50-60 Hz input.

• Single and Three Phase Power.

• < 95% Power factor – optimizes available electrical
capacity / especially useful when limited to inputs of
230VAC – 1 phase.

• Environmentally Hardened - IP23 rated for operating
in difficult environments.

• Versatile Feeding Options – Standard Mig guns,
Spool guns, and Push-pull guns.

• Ethernet connectivity – allows access to the Power
Wave utilities software tools.

®

C300 will provide the following:

RECOMMENDED PROCESSES AND
EQUIPMENT

RECOMMENDED PROCESSES

The Power Wave®C300 is a high speed, multi-process
power source capable of regulating the current, voltage, or
power of the welding arc. With an output range of 5 to 300
amperes, it supports a number of standard processes
including synergic GMAW, GMAW-P, FCAW, FCAW-SS,
SMAW, GTAW and GTAW-P on various materials especial­ly steel, aluminum and stainless steel.

B-2

PROCESS LIMITATIONS

The software based weld tables of the Power Wave®C300
limit the process capability within the output range and the
safe limits of the machine. In general the processes will be
limited to .025-.045 solid steel wire, .035-.045 stainless wire,
.035-.052 cored wire, and .035 and 3/64 Aluminum wire.
1/16 Aluminum wire is not supported.

The following items will not be supported on this product,
but may be supported by other product in the product portfo­lio:

• STT

• AC welding processes

WARNING

The Power Wave®C300 is not recommended for pipe
thawing.

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EQUIPMENT LIMITATIONS

• Maximum gun length is 25 ft (7.6m) for push-only
systems.

• Maximum gun length is 50 ft (15.2) for push-pull
systems.

• Maximum spool size is 12 in (305 mm) diameter.

• Maximum spool weight is 44 lb (20 kg).

• Other gun bushings are required for welding guns
that do not have a Magnum (Tweco #2-#4 compati­ble) back end.

The following capabilities are supported:

• Push-pull (12-pin) connection - Panther™ and Cougar™.

• 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 connections.

• Gas / Stud adapter (K2505-2) allow for easy TIG connec­tions.

• Simple process to switch between different welding
processes.

POWER WAVE®C300