Page 1 POWER WAVE C300 ® For use with machines having Code Numbers: 11479, 11624, 11672, 11958, 12392 SERVICE MANUAL Need Help? Call 1.888.935.3877 to talk to a Service Representative Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri. After hours? Use “Ask the Experts”...
Page 2 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.
Page 3 SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. 7.a. Use only compressed cylinders explosion. containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
Page 6 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.
Page 7 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 recommen- dations.
Page 8 POWER WAVE® C300...
Page 9 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Theory of Operation .
Page 10 FIGURE E.1 BLOCK LOGIC DIAGRAM SWITCH BOARD POWER WAVE C300 BLOCK DIAGRAM ( ( S S E E C C O O N N D D S S T T A A G G E E ) ) H H I I G G H H F FR R E E Q Q U U E E N N C C Y Y I IN N V V E E R R T T E E R R W W IT ITH H...
Page 11 FIGURE E.2 - GENERAL DESCRIPTION SWITCH BOARD POWER WAVE C300 BLOCK DIAGRAM ( ( S S E E C C O O N N D D S S T T A A G G E E ) ) H H I I G G H H F FR R E E Q Q U U E E N N C C Y Y I IN N V V E E R R T T E E R R W W IT ITH H...
Page 12 FIGURE E.3 - MAIN INPUT SWITCH, INPUT RECTIFIER, SOFT START/INPUT RELAY, ETC. SWITCH BOARD POWER WAVE C300 BLOCK DIAGRAM ( ( S S E E C C O O N N D D S S T T A A G G E E ) )
Page 13 FIGURE E.4 - PLANAR TRANSFORMER, OUTPUT RECTIFICATION AND FILTERING SWITCH BOARD POWER WAVE C300 BLOCK DIAGRAM ( ( S S E E C C O O N N D D S S T T A A G G E E ) )
Page 14: Table Of Contents
FIGURE E.5 - CHOPPER, CURRENT TRANSDUCER AND CONTROL BOARDS SWITCH BOARD POWER WAVE C300 BLOCK DIAGRAM ( ( S S E E C C O O N N D D S S T T A A G G E E ) )
Page 15: Power Wave C300 Block Diagram
FIGURE E.6 - FEEDHEAD BOARD & USER INTERFACE BOARD SWITCH BOARD POWER WAVE C300 BLOCK DIAGRAM ( ( S S E E C C O O N N D D S S T T A A G G E E ) )
Page 16 THEORY OF OPERATION Machine Protection THERMAL PROTECTION Three normally closed (NC) thermostats protect the machine from excessive operating temperatures. Two ther- mostats are wired in series and connected to the control board. One of the thermostats is located in the output choke assembly and the other is located on top of the secondary heat sink.
Page 17 THEORY OF OPERATION FIGURE E.7 - IGBT OPERATION MINIMUM OUTPUT 16.6 MAXIMUM OUTPUT 16.6 PULSE WIDTH MODULATION MAXIMUM OUTPUT By holding the gate signals on for 7.3 microseconds The term PULSE WIDTH MODULATION (PWM) is each and allowing only 2 microseconds of dwell or off used to describe how much time is devoted to conduc- time (one microsecond during each half cycle) during tion in the positive and negative portions of the cycle.
Page 18 THEORY OF OPERATION FIGURE E.8 - IGBT OPERATION POSITIVE VOLTAGE APPLIED GATE GATE SOURCE SOURCE BODY REGION BODY REGION DRAIN DRIFT REGION DRAIN DRIFT REGION BUFFER LAYER BUFFER LAYER INJECTING LAYER INJECTING LAYER DRAIN DRAIN A. PASSIVE B. ACTIVE INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor.
Page 19 NOTES E-10 E-10 POWER WAVE® C300...
Page 20 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .
Page 21: Troubleshooting And Repair
HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 22: Pc Board Troubleshooting Procedures
Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
Page 23 Board Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE® C300...
Page 24: From The Output Terminals
CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE® C300...
Page 25 Check Set-Up menu ”P.8” CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE® C300...
Page 26 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE® C300...
Page 27 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE® C300...
Page 28 Test. used. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE® C300...
Page 29 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWER WAVE® C300...
Page 30 TROUBLESHOOTING AND REPAIR F-11 F-11 USING THE STATUS LED TO There is an audible beeper associated with this input control TROUBLESHOOT SYSTEM PROBLEMS board’s status light. So the error codes on the input board can be detected through either the status light or the status beeper.
Page 31 TROUBLESHOOTING AND REPAIR F-12 F-12 Observe all Safety Guidelines detailed throughout this manual ERROR CODES FOR THE POWER WAVE® C300 Main control boarD ( “status” light) Error Code # Indication Thermal error Indicates over temperature. Usually accompanied by Thermal LED. Check fan operation.
Page 32 TROUBLESHOOTING AND REPAIR F-13 F-13 Observe all Safety Guidelines detailed throughout this manual input control boarD Error Code # Indication Peak input current limit Input current limit has been exceeded. Typically indicates short term power overload. If problem persists contact Service Department. Under-voltage lockout +15 VDC supply on Input control board too low.
Page 33 NOTES F-14 F-14 POWER WAVE® C300...
Page 34 DISCHARGE PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 35 TROUBLESHOOTING AND REPAIR F-16 F-16 CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.1 – CASE COVER SCREW LOCATION PROCEDURE 5. Recheck the voltage across the capacitor ter- minals. The voltage should be zero. If any volt- 1.
Page 36 TROUBLESHOOTING AND REPAIR F-17 F-17 CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.2 – CAPACITOR LOCATION CHOPPER CONTROL BOARD PLANAR TRANSFORMER DC LINK CAPACITOR CURRENT TRANSDUCER INPUT CHOKE CAPACITOR DISCHARGE PROCEDURE DO NOT TOUCH THE CAPACITOR TERMINALS WITH YOUR BARE HANDS.
Page 37: Dc Link Capacitor
TROUBLESHOOTING AND REPAIR F-18 F-18 CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.3 – CAPACITOR TERMINALS AND ASSOCIATED LEADS CAPACITOR TERMINALS DC LINK CAPACITOR POWER WAVE® C300...
Page 38 CONTROL BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 39: Fan Control
TROUBLESHOOTING AND REPAIR F-20 F-20 CONTROL BOARD TEST PROCEDURE (continued) PROCEDURE 6. If further testing is required proceed to Step #7. 1. Disconnect the input power to the POWER WAVE® C300 machine. 7. Using the Voltmeter carefully check the volt- ages per Table F2.
Page 40 TROUBLESHOOTING AND REPAIR F-21 F-21 CONTROL BOARD TEST PROCEDURE (continued) TABLE F.3 - CONTROL BOARD ASSOCIATED RESISTANCE Conditions Description Test Points Lead Numbers Expected Readings Connection to J9 pin 3 Lead 202 Zero Ohms No Input power Output applied to Terminals Negative Negative...
Page 41 TROUBLESHOOTING AND REPAIR F-22 F-22 CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.4 – LED LOCATIONS G 4 8 0 0 C O N T R O L P .C . B O A R D L E D # C O L O R F U N C T IO N G R E E N S T A T U S "...
Page 42 TROUBLESHOOTING AND REPAIR F-23 F-23 CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.5 – TEST POINT LOCATIONS Switch J12 - Chopper Control Board Communication Bank 2 CAN Communication - J11 J5 - Secondary Thermostat Connection Switch Bank 1 J6 - Primary Error Communications +48 Volt DC Connection - J4 J7 - Inverter Shutdown Command Fan Control...
Page 43 TROUBLESHOOTING AND REPAIR F-24 F-24 CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.6 – PLUGS & LEAD LOCATIONS PLUG J4 PLUG J5 PLUG J6 PLUG J7 PLUG J9 PLUG J8 PLUG J12 POWER WAVE® C300...
Page 44 SWITCH BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 45 TROUBLESHOOTING AND REPAIR F-26 F-26 SWITCH BOARD TEST PROCEDURE (continued) TABLE F.4 - SWITCH BOARD LED’s Description Indicates Light Conditions LED 1 +48VDC Supply Power applied to PW C300 LED 4 +15VDC Supply Power applied to PW C300 LED 3 Boost Circuit *When high input Active...
Page 46 TROUBLESHOOTING AND REPAIR F-27 F-27 SWITCH BOARD TEST PROCEDURE (continued) FIGURE F.7 - SWITCH BOARD LOCATION INVE RTE R CHO KE L12741 C HO PPE R CO NTRO L PCB PLANAR TRANSF O RME R INPUT C HO KE DC LINK CAPACITOR PRE-CHARGE RELAY G4770 SWITCHBOARD PCB...
Page 47 TROUBLESHOOTING AND REPAIR F-28 F-28 SWITCH BOARD TEST PROCEDURE (continued) FiGURE F.8 – SWITCH BOARD LED’s LED’S 5 THRU 10 LED 4 LED 1 LED 3 LED 11 LED’S 5 Thru 10 These six LED’s are used to indicate a turn-on of a chopper phase.
Page 48: Control Board Test
TROUBLESHOOTING AND REPAIR F-29 F-29 SWITCH BOARD TEST PROCEDURE (continued) TABLE F.5 – SWITCH BOARD VOLTAGE MEASUREMENTS Description Test Points Expected Reading Conditions Pre-Charge Relay Plug J41 Pin 6(-) 15VDC Correct input power Coil Voltage applied to machine Plug J41 Pin 5(+) and pre-charge completed.
Page 49 TROUBLESHOOTING AND REPAIR F-30 F-30 SWITCH BOARD TEST PROCEDURE (continued) TABLE F.6 – SWITCH BOARD RESISTANCE MEASUREMENTS Description Meter Test Points Expected Readings Conditions and Polarity 100 O hm Pre -Ch arge B10( +) 100 Ohms Machine “o ff” no Resistor input power applied B12 (-)
Page 50 TROUBLESHOOTING AND REPAIR F-31 F-31 SWITCH BOARD TEST PROCEDURE (continued) TABLE F.6 – SWITCH BOARD RESISTANCE MEASUREMENTS (continued) Full Bridge Low Sid e B37( +) To High Resistance Machine “o ff” no IGB Ts B49( -) Greate r than input power applied. Also 10,000 ohms The Pla nar...
Page 51 TROUBLESHOOTING AND REPAIR F-32 F-32 SWITCH BOARD TEST PROCEDURE (continued) FIGURE F.9 – SWITCH BOARD TEST POINTS INVERTER CHOKE PLUG J41 POWER WAVE® C300...
Page 52 POWER FACTOR CONTROL BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 53 TROUBLESHOOTING AND REPAIR F-34 F-34 POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) PROCEDURE 9. If further testing is required remove the input 1. Disconnect the input power to the POWER power to the machine and perform the resis- WAVE® C300 machine. tance checks in Table F.8.
Page 54: Pfc Control Board
TROUBLESHOOTING AND REPAIR F-35 F-35 POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.10 – P.F.C. CONTROL BOARD LOCATION PF C CO NTRO L BO ARD E THE RNE T RE C E PTAC LE DC LINK C APAC ITO R PRE -C HARG E RE LAY INPUT C O RD G RIP G AS SO LE NO ID...
Page 55 TROUBLESHOOTING AND REPAIR F-36 F-36 POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.11 – P.F.C. CONTROL BOARD PLUGS LED 1 LED 2 BUZZER G5915 P.F.C. CONTROL BOARD P.C. BOARD LED # COLOR FUNCTION GREEN 15 VDC POWER SUPPLY FUNCTION PROPERLY WHEN ON ERROR CODE (LED WILL FLASH ERROR AND BUZZER WILL SOUND) SEE TABLE BELOW FOR DETAILS •...
Page 56 TROUBLESHOOTING AND REPAIR F-37 F-37 POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) TABLE F.8 - POWER FACTOR CORRECTION CONTROL BOARD RESISTANCE CHECKS Description Meter Test Points Expected Readings Conditions and Polarity Auxiliary Power Receptacle J27 Pin Ver y High Input power Input Circuit 3 (-) resistance.
Page 57 TROUBLESHOOTING AND REPAIR F-38 F-38 POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) TABLE F8 - POWER FACTOR CORRECTION CONTROL BOARD RESISTANCE CHECKS (continued) Main Boost Gate Plug J23 Pin 8 (-) Resistance should Input power Drive be greater than 500 removed.
Page 58 TROUBLESHOOTING AND REPAIR F-39 F-39 POWER FACTOR CONTROL BOARD TEST PROCEDURE (continued) FIGURE F.12 – PLUG J23 PLUG J27 FIGURE F.13 – SWITCH BOARD TEST POINTS POWER WAVE® C300...
Page 59 NOTES F-40 F-40 POWER WAVE® C300...
Page 60 CURRENT AND VOLTAGE CALIBRATION PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 61 TROUBLESHOOTING AND REPAIR F-42 F-42 CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued) CALIBRATION SET-UP: 1. Load the Power Wave Manager Software into CALIBRATION PROCEDURE: the computer. 1. Once in the “Calibration” screen, make sure that the machine output is OFF (light is BLACK) 2.
Page 62 TROUBLESHOOTING AND REPAIR F-43 F-43 CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued) FIGURE F.14 – CALIBRATION SCREEN POWER WAVE® C300...
Page 63 NOTES F-44 F-44 POWER WAVE® C300...
Page 64 USER INTERFACE BOARD TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 65 TROUBLESHOOTING AND REPAIR F-46 F-46 USER INTERFACE BOARD TEST PROCEDURE (continued) PROCEDURE 1. Disconnect the input power to the POWER WAVE® C300 machine. 2. To gain access to the User Interface Board test points first perform the Case Cover and DC Link Capacitor Discharge Procedure.
Page 66 TROUBLESHOOTING AND REPAIR F-47 F-47 USER INTERFACE BOARD TEST PROCEDURE (continued) POWER WAVE® C300...
Page 67 TROUBLESHOOTING AND REPAIR F-48 F-48 USER INTERFACE BOARD TEST PROCEDURE (continued) FIGURE F.15 – U.I. FRONT VIEW (G4760 Series) DISP 6 DISP 7 LED 11 LED 13 LED 14 LED 12 LED 15 LED 10 DISP 1 DISP 2 DISP 3 LED 9 LED 16 IR PORT...
Page 68 TROUBLESHOOTING AND REPAIR F-49 F-49 USER INTERFACE BOARD TEST PROCEDURE (continued) FIGURE F.16 – PLUG J5 LOCATION ON USER INTERFACE BOARD (rear view) 357 B 541 B PLUG J5 48 VDC 359 B 542 B NOTE: Leads connect to Plug J81 on the Feed head Board POWER WAVE®...
Page 69 NOTES F-50 F-50 POWER WAVE® C300...
Page 70 INPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 71: Chopper Control Board
TROUBLESHOOTING AND REPAIR F-52 F-52 INPUT RECTIFIER TEST PROCEDURE (continued) FIGURE F.17 – INPUT RECTIFIER LOCATION C HO PPE R C O NTRO L BO ARD PLANA R T RANSF O RME R INPUT RECTIFIER TEST POINTS C URRE NT TRANSDUC E R O N/O F F SW ITC H PROCEDURE INPUT C HO K E...
Page 72 TROUBLESHOOTING AND REPAIR F-53 F-53 INPUT RECTIFIER TEST PROCEDURE (continued) FIGURE F.18 – INPUT RECTIFIER LEAD LOCATIONS TABLE F.11 – PROBE READINGS +Probe (RED) -Probe (BLACK) RESULT Terminal B32 Terminal B10 0.3V - 1.0V Terminal B31 Terminal B10 0.3V - 1.0V Terminal B30 Terminal B10 0.3V - 1.0V...
Page 73 NOTES F-54 F-54 POWER WAVE® C300...
Page 74 GAS SOLENOID TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 75 TROUBLESHOOTING AND REPAIR F-56 F-56 GAS SOLENOID TEST PROCEDURE (continued) PROCEDURE 10. If the correct solenoid voltage is not present at 1. Disconnect the input power to the POWER the solenoid terminals check for the correct WAVE® C300 machine. voltage at plug J83 pins 3 and 4 on the FeedHead PC Board.
Page 76 TROUBLESHOOTING AND REPAIR F-57 F-57 GAS SOLENOID TEST PROCEDURE (continued) FIGURE F.19 – GROUNDING LUG GROUNDING LUG HINGED COVER GAS SOLENOID TOP VIE W DE TAIL OF INPUT CO NNE CT ION FIGURE F.20 – PLUG J83 POWER WAVE® C300...
Page 77 NOTES F-58 F-58 POWER WAVE® C300...
Page 78 PLANAR TRANSFORMER RESISTANCE TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 79 TROUBLESHOOTING AND REPAIR F-60 F-60 PLANAR TRANSFORMER RESISTANCE TEST PROCEDURE (continued) FIGURE F.21 - TEST POINTS INVERTER CHOKE PROCEDURE 1. Disconnect the input power to the POWER WAVE® C300 machine. 2. To gain access to the Planar Transformer test points first perform the Case Cover and DC Link Capacitor Discharge Procedure.
Page 80 TROUBLESHOOTING AND REPAIR F-61 F-61 PLANAR TRANSFORMER RESISTANCE TEST PROCEDURE (continued) TABLE F.12 – RESISTANCE CHECKS Test Points E xpected Resistance Comments Reading B 37 to B 41 Z er o ohms Continuity of Primary Winding B 39 to B 40 Z e r o ohms Continuity of Secondary Winding...
Page 81 NOTES F-62 F-62 POWER WAVE® C300...
Page 82 FeedHead BOARD AND TACHOMETER FEEDBACK TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 83: Gun Trigger
TROUBLESHOOTING AND REPAIR F-64 F-64 FeedHead BOARD AND TACHOMETER FEEDBACK TEST PROCEDURE (continued) TABLE F.13 – FeedHead BOARD TEST POINTS Description Test Points Lead Expected Conditions Numbers Readings Power Supply Plug J82 Pin 3 Lead 357(-) 48VDC Input power to Board applied to Plug 82 Pin4 Lead 359(+)
Page 84 TROUBLESHOOTING AND REPAIR F-65 F-65 FeedHead BOARD AND TACHOMETER FEEDBACK TEST PROCEDURE (continued) FIGURE F.22 – FEEDHEAD BOARD PLUG LOCATION PLUG J84 PLUG J83 PLUG J82 PLUG J81 359B 357B 554 (to diode bridge) 640 (to diode bridge) POWER WAVE® C300...
Page 85 NOTES F-66 F-66 POWER WAVE® C300...
Page 86 WIRE DRIVE MOTOR TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 87 TROUBLESHOOTING AND REPAIR F-68 F-68 WIRE DRIVE MOTOR TEST PROCEDURE (continued) FIGURE F.23 – WIRE DRIVE MOTOR LOCATION PLUG P11 WIRE DRIVE MOTOR PROCEDURE 6. If the resistance measurements are correct in 1. Disconnect the input power to the POWER Step 5 then using the variable DC Power WAVE®...
Page 88 OUTPUT RECTIFIER TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 89 TROUBLESHOOTING AND REPAIR F-70 F-70 OUTPUT RECTIFIER TEST PROCEDURE (continued) FIGURE F.24 – TEST POINTS PROCEDURE open. 1. Disconnect the input power to the POWER WAVE® C300 machine. 5. If the Output Rectifier is faulty the entire Switch Board must be replaced. 2.
Page 90: Current Transducer
CURRENT TRANSDUCER TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 91: Current Transducer Test
TROUBLESHOOTING AND REPAIR F-72 F-72 CURRENT TRANSDUCER TEST PROCEDURE (continued) PROCEDURE 8. Connect a load bank (or 50 Ft. weld cable) to the Positive and Negative output terminals on 1. Disconnect the input power to the POWER the POWER WAVE® C 300. WAVE®...
Page 92: Fan Control
TROUBLESHOOTING AND REPAIR F-73 F-73 CURRENT TRANSDUCER TEST PROCEDURE (continued) FIGURE F.25 – PLUG LOCATIONS ON CONTROL BOARD J12 - Chopper Control Board Communication J5 - Secondary Thermostat Connection Switch Bank 1 J6 - Primary Error Communications J7 - Inverter Shutdown Command Fan Control Status LED J8 - Current Feedback...
Page 93 TROUBLESHOOTING AND REPAIR F-74 F-74 CURRENT TRANSDUCER TEST PROCEDURE (continued) FIGURE F.26 – CURRENT TRANSDUCER LOCATION DIG ITA L C O NTRO L BO ARD F E E DHE A D BO A RD C URRE NT TRANSDUC E R TABLE F.14 Output Current (Actual) T r ansducer F eedback Voltage...
Page 94 TROUBLESHOOTING AND REPAIR F-75 F-75 CURRENT TRANSDUCER TEST PROCEDURE (continued) FIGURE F.27 – ETHERNET RECEPTACLE E THE RNE T RE C E P TAC LE POWER WAVE® C300...
Page 95 NOTES F-76 F-76 POWER WAVE® C300...
Page 96: Removal And Replacement Procedures
REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 97 TROUBLESHOOTING AND REPAIR F-78 F-78 POWER FACTOR CORRECTION CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.28 – CAPACITOR & P.F.C. CONTROL BOARD LOCATION PF C CO NTRO L BO ARD DC LINK C APAC ITO R PROCEDURE 5. Remove the five molex type plugs from the 1.
Page 98: Current Transducer (Lem
REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 99 TROUBLESHOOTING AND REPAIR F-80 F-80 CURRENT TRANSDUCER (LEM) REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.29 – CURRENT TRANSDUCER LOCATION O UT PUT C HO KE C URRE NT TRANSDUC E R O N/O F F SW ITC H PROCEDURE INPUT C HO K E 7.
Page 100: Control Board
CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 101: Control Board
TROUBLESHOOTING AND REPAIR F-82 F-82 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.30 – CONTROL BOARD LOCATION DIG ITA L C O NTRO L BO ARD F E E DHE A D BO A RD PROCEDURE 7. Install the new board and replace the molex 1.
Page 102: Control Board
TROUBLESHOOTING AND REPAIR F-83 F-83 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.31 – BOARD PLUG REMOVAL Switch J12 - Chopper Control Board Communication Bank 2 CAN Communication - J11 J5 - Secondary Thermostat Connection Switch Bank 1 J6 - Primary Error Communications +48 Volt DC Connection - J4 J7 - Inverter Shutdown Command Fan Control...
Page 103 NOTES F-84 F-84 POWER WAVE® C300...
Page 104 FeedHead BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 105 TROUBLESHOOTING AND REPAIR F-86 F-86 FeedHead BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.32 – FeedHead BOARD LOCATION F E E DHE A D BO A RD PROCEDURE 7. If a spool gun board is plugged into the 1. Disconnect the input power to the POWER FeedHead Board carefully remove it.
Page 106 SWITCH BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 107: Switch Board Assembly
TROUBLESHOOTING AND REPAIR F-88 F-88 SWITCH BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.33 – SWITCH BOARD LOCATION & MOUNTING SCREWS MOUNTING SCREWS (4) INPUT CHOKE SWITCH BOARD ASSEMBLY PROCEDURE 7. Using the 7/16” wrench, remove the two input 1.
Page 108: Input Choke
TROUBLESHOOTING AND REPAIR F-89 F-89 SWITCH BOARD ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.34 – SWITCH BOARD LEADS CHOPPER POSITIVE OUTPUT BOARD CABLE CONNECTION PLUG J45 CONNECTOR OUTPUT CHOKE CONNECTIONS LEAD A LEAD A2 LEAD A3 LEAD A4 LEAD A5 LEAD A6 PLUG J43 INPUT PHASE...
Page 109 NOTES F-90 F-90 POWER WAVE® C300...
Page 110 WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 111: Wire Drive Assembly
TROUBLESHOOTING AND REPAIR F-92 F-92 WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.35 – WIRE DRIVE ASSEMBLY LOCATION WIRE DRIVE MOUNTING ASSEMBLY NUTS GUT TRIGGER RECEPTACLE (2 SCREWS) POSITIVE OUTPUT HOSE TERMINAL CONNECTION PROCEDURE 5. Using the 11/16 inch wrench remove the gas 1.
Page 112 TROUBLESHOOTING AND REPAIR F-93 F-93 WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) 8. Carefully place the new Wire Drive Assembly into position and connect Plug J83 into the wiring harness. 9. Mount the gun trigger receptacle into the Wire Drive Assembly.
Page 113 NOTES F-94 F-94 POWER WAVE® C300...
Page 114 USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 115: User Interface Board
TROUBLESHOOTING AND REPAIR F-96 F-96 USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 12. Remove the bypass grounding assembly from 1. Disconnect the input power to the POWER the User Interface Board. WAVE® C300 machine. 13. Locate and remove the other two slot head 2.
Page 116 TROUBLESHOOTING AND REPAIR F-97 F-97 USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.36 – USER INTERFACE BOARD LOCATION USER INTERFACE BOARD PF C CO NTRO L BO ARD DC LINK C APAC ITO R POWER WAVE® C300...
Page 117 TROUBLESHOOTING AND REPAIR F-98 F-98 USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.37 – KNOBS FOUR SCREWS THREE KNOBS POWER WAVE® C300...
Page 118 TROUBLESHOOTING AND REPAIR F-99 F-99 USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.38 – USER INTERFACE BOARD COVER PLATE USER INTERFACE BOARD COVER PLATE POWER WAVE® C300...
Page 119 NOTES F-100 F-100 POWER WAVE® C300...
Page 120: Retest After Repair
Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877. TEST DESCRIPTION This procedure will aid the technician in testing the Power Wave C300 output after the repair or replacement of a part or PC board. MATERIALS NEEDED...
Page 121 NOTES F-102 F-102 POWER WAVE® C300...
Page 122: Chopper Module Output Test
CHOPPER MODULE OUTPUT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 123 TROUBLESHOOTING AND REPAIR F-104 F-104 CHOPPER MODULE OUTPUT TEST (continued) FIGURE F.39 – CHOPPER MODULE OUTPUT TEST PROCEDURE Test Acceptable Component Lead 1. Perform the Case Cover Removal Procedure Point Value Tested 2. Connect the output terminals to a load bank Positive Machine Output 300A 3.
Page 124 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (G6128) .
Page 125 ELECTRICAL DIAGRAMS WIRING DIAGRAM - (G6128) (PG. 1 0F 2) ENGINEERING CONTROLLED CHANGE DETAIL: PAGE 1, FRED PC BOARD, CHANGED "1J81 THRU 4J81" TO "1J31 THRU 4J31". PAGE 2, FRED PC BOARD, FRONT, REMOVED "J2" AND "J4". BACK, CHANGED "J3" TO "J32" AND "J5" TO "J31". MANUFACTURER: SWITCHBOARD PC BOARD, CHANGED "LED11"...
Page 126: Switchboard
SWITCHBOARD PC BOARD, CHANGED "LED11" TO "LED2". PFC CONTROL CONTROL P.C. BOARD P.C. BOARD P.C. BOARD Description of LED functions on Power Wave C300 Description of LED functions For reference only on Power Wave C300 INPUT CONTROL & PWR G5915-1 For reference only G4770 SWITCHBOARD P.C.
Page 127 ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE (G6052) FOOT AMPTROL CAVITY NUMBERING SEQUENCE CONNECTOR (VIEWED FROM COMPONENT SIDE OF P.C. BOARD) J10A1, J9, J13, J26, J2, J5, J11, J10B1, J27, J83,J88 (VIEWED FROM REAR) J81, J82 J811 CONTROL BOARD J8, J24, G4800 J3, J4, J28, J43,...
Page 128 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 1 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 129 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 2 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 130 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 3 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 131 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 4 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 132 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 5 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 133 ELECTRICAL DIAGRAMS G-10 G-10 SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 6 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 134 ELECTRICAL DIAGRAMS G-11 G-11 SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 7 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 135 ELECTRICAL DIAGRAMS G-12 G-12 SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 8 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 136 ELECTRICAL DIAGRAMS G-13 G-13 SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 9 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 137 ELECTRICAL DIAGRAMS G-14 G-14 SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 10 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 138 ELECTRICAL DIAGRAMS G-15 G-15 SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 11 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 139 ELECTRICAL DIAGRAMS G-16 G-16 SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 12 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 140 ELECTRICAL DIAGRAMS G-17 G-17 SCHEMATIC - CONTROL PC BOARD (G4799) (PG. 13 OF 13) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 141 ELECTRICAL DIAGRAMS G-18 G-18 SCHEMATIC - INPUT CONTROL PC BOARD (G5914) (PG. 1 OF 3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 142 ELECTRICAL DIAGRAMS G-19 G-19 SCHEMATIC - INPUT CONTROL PC BOARD (G5914) (PG. 2 OF 3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 143 ELECTRICAL DIAGRAMS G-20 G-20 SCHEMATIC - INPUT CONTROL PC BOARD (G5914) (PG. 3 OF 3) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 144 ELECTRICAL DIAGRAMS G-21 G-21 SCHEMATIC - 3 STAGE INVERTER PC BOARD (G4769) (PG. 1 OF 2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 145 ELECTRICAL DIAGRAMS G-22 G-22 SCHEMATIC - 3 STAGE INVERTER PC BOARD (G4769) (PG. 2 OF 2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 146 ELECTRICAL DIAGRAMS G-23 G-23 SCHEMATIC - F.R.E.D. PC BOARD (G4758) (PG. 1 OF 7) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 147 ELECTRICAL DIAGRAMS G-24 G-24 SCHEMATIC - F.R.E.D. PC BOARD (G4758) (PG. 2 OF 7) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 148 ELECTRICAL DIAGRAMS G-25 G-25 SCHEMATIC - F.R.E.D. PC BOARD (G4758) (PG. 3 OF 7) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 149 ELECTRICAL DIAGRAMS G-26 G-26 SCHEMATIC - F.R.E.D. PC BOARD (G4758) (PG. 4 OF 7) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 150 ELECTRICAL DIAGRAMS G-27 G-27 SCHEMATIC - F.R.E.D. PC BOARD (G4758) (PG. 5 OF 7) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 151 ELECTRICAL DIAGRAMS G-28 G-28 SCHEMATIC - F.R.E.D. PC BOARD (G4758) (PG. 6 OF 7) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 152 ELECTRICAL DIAGRAMS G-29 G-29 SCHEMATIC - F.R.E.D. PC BOARD (G4758) (PG. 7 OF 7) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 153 ELECTRICAL DIAGRAMS G-30 G-30 SCHEMATIC - 42 VOLT & ARCLINK FEEDER PC BOARD (G3883) (PG. 1 OF 2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 154 ELECTRICAL DIAGRAMS G-31 G-31 SCHEMATIC - 42 VOLT & ARCLINK FEEDER PC BOARD (G3883) (PG. 2 OF 2) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...
Page 155 ELECTRICAL DIAGRAMS G-32 G-32 SCHEMATIC - SPOOL GUN PC BOARD (L12008) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER WAVE® C300...

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