SVM 1047 PW345C

Page Accueil
SVM 1047-A
September 2004
PW 345 C
For machines with Code Number F1044-F1076-54015
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.
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Declaration of conformity
LINCOLN ELECTRIC FRANCE

Declares that the welding machine:
POWER WAVE 345C s/n
conforms to the following directives:
73/23/CEE, 89/336/CEE
and has been designed in conformance with the following norms:
EN 50199, EN 60974-1, EN 60974-5
LINCOLN ELECTRIC FRANCE, Avenue Franklin Roosevelt, 76121 Le Grand-Quevilly cedex, France
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This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and
repair procedures are performed only by qualified individuals. Read and understand this manual before operating
this equipment. Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or
damage to this equipment. Read and understand the following explanations of the warning symbols. Lincoln
Electric is not responsible for damages caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal
injury, loss of life, or damage to this equipment. Protect yourself and others from possible serious
injury or death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual
could cause serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous
to health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: 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. Use suitable clothing made from
durable flame-resistant material to protect you skin and that of your helpers. Protect other nearby
personnel with suitable, non-flammable screening and warn them not to watch the arc nor expose
themselves to the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the
welding process can easily go through small cracks and openings to adjacent areas. Do not weld on
any tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at
the fuse box before working on this equipment. Ground this equipment in accordance with local
electrical regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work
clamp cables. If any insulation damage exists replace the cable immediately. Do not place the
electrode holder directly on the welding table or any other surface in contact with the work clamp to
avoid the risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through
any conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker should consult their physician before operating this
equipment.
CYLINDER MAY EXPLODE IF DAMAGED: 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. Always keep cylinders in an upright position securely chained to a fixed support. Do
not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.
CE COMPLIANCE: This equipment complies to the European Communities directives.
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Electromagnetic Compatibility (EMC)
This machine has been designed in accordance with all relative directives and norms. However, it may still
generate electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio,
and television) or other safety systems. These disturbances can cause safety problems in the affected systems.
Read and understand this section to eliminate or reduce the amount of electromagnetic disturbance generated by
this machine.
WARNING: This machine has been designed to operate in an industrial area. To operate in a
domestic area it is necessary to observe particular precautions to eliminate possible
electromagnetic disturbances. The operator must install and operate this equipment as described
in this manual. If any electromagnetic disturbances are detected the operator must put in place
corrective actions to eliminate these disturbances with, if necessary, assistance from Lincoln
Electric France. Do not modify this machine without the written approval of Lincoln Electric.
Before installing the machine, the operator must check the work area for any devices that may malfunction
because of electromagnetic disturbances. Consider the following.
• Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
machine.
• Radio and/or television transmitters and receivers.
• Computers or computer controlled equipment.
• Safety and control equipment for industrial processes.
• Personal medical devices like pacemakers and hearing aids.
• Equipment for calibration and measurement.
• Check the electromagnetic immunity for equipment operating in or near the work area. The operator must
be sure that all equipment in the area is compatible. This may require additional protection measures.
• The dimensions of the work area to consider will depend on the construction of the area and other activities
that are taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
• Connect the machine to the input supply according to this manual. If disturbances occur if may be
necessary to take additional precautions such as filtering the input supply.
• The output cables should be kept as short as possible and should be positioned together.
• If possible connect the work piece to ground in order to reduce the electromagnetic emissions. The operator
must check that connecting the work piece to ground does not cause problems or unsafe operating
conditions for personnel and equipment.
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Installation
! Technical specification
! Safety precautions
! Location and Ventilation
! Electrical Input Connection
! Reconnect procedure
! Output Connections
Operation
! Safety precautions
! General Description
! Controls and setting
! Welding Operation
! Overload Protection
! Auxiliary Power
Accessories
! Options / Accessories
! Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders
Maintenance
! Safety Precautions
! Routine and Periodic Maintenance
! Major Component Locations
Theory of Operation
! General Description
! Input Line Voltage & Main Transformer
! Input Rectifier, Chopper Assembly and Feedback
! Diode Control Rectifier and Power Board
! Weld Control Board
! Wire Drive Motor and Feedback
! Thermal Protection
! Over Current Protection,
! Wire Feeder
! Overload Protection
! Insulated Gate Bipolar Transistor (IGBT) Operation
! Pulse Width Modulation
! Chopper Technology Fundamentals
Troubleshooting and Repair
! How to use Troubleshooting Guide
! PC Board Troubleshooting Procedures
! Troubleshooting Guide
! Test Procedures
! Oscilloscope Waveform
! Replacement procedures
! Retest After Repair
Parts Manual
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INSTALLATION
TECHNICAL SPECIFICATIONS – PW 345 C
INPUT
Input Voltage
Frequency
230 / 400 V
50 Hertz (Hz)
3 phase
RATED OUTPUT
Duty Cycle (acc. EN60974-1) Output Current
(Based on a 10 min. period)
35% 350 A
60% 300 A
100% 230 A
OUTPUT RANGE
Welding Current Range Auxiliary Power
5 – 350 Amps 230V AC (water cooler)
WIRE SPEED RANGE (m/min)
2 m/min to 20 m/min
WIRE SIZES (mm)
SOLID WIRES CORED WIRES ALU WIRES
0.6 to 1.6 1.0 to 1.6 1.0 to 1.6
DIMENSIONS
Weight ( Kg)
Heigth (mm) Width (mm) Length ( mm)
135 (air)
880 680 1100
162 (water)
Operating Temperature Storage Temperature
–20°C to +40°C -25°C to 55°C
For any maintenance or repair operations it is recommended to contact the nearest Lincoln technical service
center. Maintenance or repairs preformed by unauthorized service centers or personnel will null and void the
manufacturers warranty.
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INSTALLATION
Safety Precaution
• Do not touch electrically live parts such as output terminals or

internal wiring.
• Insulate yourself from the work and ground.
• Turn power switch off before connecting or disconnecting
cables or connections.
•
Always connect grounding terminal to a proper electrical
earth ground.
Only qualified personnel should install, use, or service this equipment.
Location and Ventilation

This machine will operate in harsh environments. However, it is important that simple preventative
measures are followed to assure long life and reliable operation.
• Do not place or operate this machine on a surface with an incline greater than 7° from horizontal.
• This machine must be located where there is free circulation of clean air without restrictions for air
movement to and from the air vents. Do not cover the machine with paper, cloth or rags when
switched on.
• Dirt and dust that can be drawn into the machine should be kept to a minimum.
• This machine has a protection rating of IP23. It can be used in moderate raining conditions
without causing any danger for users' safety.
• Locate the machine away from radio controlled machinery. Normal operation may adversely
affect the operation of nearby radio controlled machinery, which may result in injury or equipment
damage. Read the section on electromagnetic compatibility in this manual.
• Do not operate in areas with an ambient temperature greater than 40°C.
• The machine cannot be used for pipe thawing.
• Only operate with the right door of the machine closed.
Only use 15kg-coils, type 300 with this machine.
Input Supply Connection

Check the input voltage, phase, and frequency supplied to this machine before turning it on. The
allowable input voltage is indicated in the technical specification section of this manual and on the
rating plate of the machine. Verify the connection of grounding wires from the machine to the input
source.
The frame of this machine must be grounded. A ground terminal located on the base of the generator
is provided for this purpose.
This machine is factory 3ph-400V connected. To connect it in 3ph-230V, remove the left case panel of the
machine to have access to the input reconnect panel. Modify the connections according to the connection
diagram located on the inside of the case side.
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OPERATION
Read this entire section before installation or operation of the machine.
• Only operate with the right door of the
machine closed.
Product Description • Only use 15kg-coils, type 300 with this
machine.
The PW345C is a complete semiautomatic multi-
process DC arc welding machine offering CV and
CC DC welding. It is rated for 350Amps at 35%
and 300 amps at 60% duty cycle. The standard Input Supply Connection
machine is equipped to weld CC-Stick, CC- Check the input voltage, phase, and frequency supplied
GTAW, CV-FCAW, synergic and non-synergic to this machine before turning it on. The allowable input
CV-GMAW / synergic GMAW-P processes. The voltage is indicated in the technical specification section
digital microcomputer based control system allows of this manual and on the rating plate of the machine.
Verify the connection of grounding wires from the
easy and accurate adjustment of weld parameters machine to the input source.
through the multi-process panel located on the The frame of this machine must be grounded. A
front of the machine. The PW345C, is equipped ground terminal located on the base of the
according to the choosen version with a 3-pin generator is provided for this purpose.
connector to allow operation of a push-pull gun for This machine is factory 3ph-400V connected. To
feeding aluminum wires. connect it in 3ph-230V, remove the left case panel
It is available with : of the machine to have access to the input
- 230 VAC/ 3.5 amp auxiliary power for water reconnect
cooler. panel. Modify the connections according to the
For a quick and easy handling within the welding connection diagram located on the inside of the
area, it is factory mounted on a built-in case side.
undercarriage equipped with a platform for a gas
cylinder.
Gas Connection
Location and Environment Once a gas cylinder has been securely installed
This machine will operate in harsh environments. on the machine, connect the gas hose of the input
However, it is important that simple preventative cable to the gas cylinder using a flow regulator.
measures are followed to assure long life and
reliable operation.
• Do not place or operate this machine on a Controls on the case front
surface with an incline greater than 7° from
horizontal.
• This machine must be located where there is
free circulation of clean air without restrictions
for air movement to and from the air vents. A
Do not cover the machine with paper, cloth or
rags when switched on. B
• Dirt and dust that can be drawn into the
machine should be kept to a minimum.
C
• This machine has a protection rating of IP23.
It can be used in moderate raining conditions
without causing any danger for users' safety. D
• Locate the machine away from radio
controlled machinery. Normal operation may
E
adversely affect the operation of nearby radio
controlled machinery, which may result in
injury or equipment damage. Read the F
section on electromagnetic compatibility in
this manual. G
• Do not operate in areas with an ambient
temperature greater than 40°C.
• The machine cannot be used for pipe thawing. H
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Size 45m from 45 to
60m
300A @ 60% 70 mm²

A : Front Panel (see description below) or (Standard 95 mm²
B : Status light : A two color light that indicates 350A @ à 35% cable)
system errors. Normal operation is a steady
green light.
C : MSP3 Panel (see description below)
D : Euroconnector
E : Push Pull Receptacle (following version)
F : ON/OFF Switch : It controls the input power Drive Rolls and Guide Tubes
to the machine. Be sure the power source is Installation
connected to the mains supply before turning • Mount the wire spool on the output shaft so
power on ( "I"). that, by dragging the extremity of the wire, the
G : Remote control receptacle. spool turns anticlockwise.
H : Water connector (as standard on water
• The wire diameter must fit the diameter
cooled models) for connecting water cooled
stenciled on the visible side of drive rolls. If it
torches
is not the case, unscrew the screws holding
I : Fast Mate adaptor (Female) for Ground
the rolls, turn them or replace them with rolls
cable.
that fit the wire diameter used.
NOTA : The rating plate is located on the rear panel of
• Every drive roll is provided with 2 grooves to
the machine. allow the feeding of wires with different
diameters.
• Specific drive rolls are available for cored or
aluminium wires. It is also possible to
configure the wire feeder with 4 driven rolls
Output connections (see "Accessories").
Ground cable delivered with the machine has • Lift the levers of ball bearings which press on
Twist-mate plugs for connection to the POWER drive rolls.
WAVE 345C. • Insert the wire inside the fitting inlet guide and
Use the shortest possible cable lengths. let it out from the torch adapter. Lower the
levers regulating the bearings. Use the
adjustment nut to modify the pressure of the
Changing Polarity bearings.
Connect the output lead of the Euroconnector to
the desired polarity and the ground lead to the
other terminal:
The positive terminal marked (+) is the standard Idle Roll Pressure Setting
configuration (see photo). This polarity is mainly For small wire sizes and aluminum wires, the idle
used on GMAW and FCAW-GS welding mode. roll pressure varies with type of wire, surface
The negative terminal marked (-) is mainly used condition, lubrication and hardness.
on FCAW-SS ( Innershield) welding mode. An excessive pressure may cause wire distortion.
It may be jammed or break which may cause an
early wear and tear of the feeding motor. Turn
back the adjusting knob and repeat the operation.
A too low pressure may cause wire feeding
irregularities.
Connecting the Welding Gun

• Position the gun connector located at the end
of the torch in front of the gun connector
machine. Gently push and screw the black
locking nut.
• Connect the gun to the gun adapter.
Cable sizes for combined lengths of
• Take off the gas guide from the gun extremity
work cable and unscrew the contact tip.
The wire must feed regularly without any
Machine Lengths up to Lengths variation in wire feed speed. If it is not the
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case, or if the wire slips, increase the 1) Closing the gun trigger initiates the
pressure setting using the with the adjustment welding sequence (preflow, run in, etc.).
nut until the wire feed speed becomes regular. 2) Opening the trigger will changes the wire
• Mount again the contact tip and the gas feed speed and the Volts/Trim to the
nozzle. Be sure the that both the wire feed Crater values, and the downslope will
speed and the size of contact tip are correct. continue during the Crater time.
• Connect the work clamp to the work piece or
to the welding table making sure that the 4 Step Logic :
clamp is provided with a good quality contact With Hot/Soft Start & Crater Fill “OFF”
(the surface of work piece must be clean and 1) Closing the gun trigger initiates the
must not show any rust, paint or oily stains). welding sequence (preflow, run in, etc)
2) Opening the trigger allows the wire to
continue feeding before or after the
Internal switches (M) welding arc is established. If the arc goes
The PW345C has 3 switches located near the out the wire continues feeding.
drive roll assembly. 3) Closing the trigger again cancels the
interlock and the wire to continues
feeding.
4) Opening the trigger again ends the
welding sequence (burnback, postflow,
etc.).
M
With Hot/Soft Start “ON”:
1) Closing the gun trigger initiates the
M1 M2 M3 welding sequence (preflow, run in) and
changes the wire feed speed and the
Volts/Trim to the Hot/Soft Start values.
2) Opening the trigger continue in the
welding sequence and changes the wire
feed speed and the Volts/Trim to Welding
values.
The wire continues feeding while the welding
arc is established. If the arc goes out the wire
continues feeding.
3) Closing the trigger again cancels the
interlock and the wire to continues
feeding.
4) Opening the trigger again ends the
welding sequence (burnback, postflow,
etc.).
M1. 2/4 strokes switch
With Crater Fill “ON”:
2 Step Logic : 1) Closing the gun trigger initiates the
welding sequence (preflow, run in, etc.).
With Hot/Soft Start & Crater Fill “OFF” 2) Opening the trigger allows the wire to
1) Closing the gun trigger initiates the continue feeding before or after the
welding sequence (preflow), run in, etc.) welding arc is established. If the arc goes
2) Opening the gun trigger ends the welding out the wire continues feeding.
sequence (burnback, postflow, etc. 3) Closing the trigger again cancels the
interlock changes the wire feed speed and
With Hot/Soft Start “ON”: the Volts/Trim to the Crater values, and
1) Closing the gun trigger initiates the the wire continues feeding.
welding sequence (preflow, run in) and 4) Opening the trigger again ends the
changes the wire feed speed and the welding sequence (burnback, postflow,
Volts/Trim to the Hot/Soft Start values. etc.).
After the Hot/Soft Start time, the welding
sequence continues and changes the wire M2.Water/air cooled torch selection switch (as
feed speed and the Volts/Trim to Welding standard on water cooled models). Set this switch
values. according to the torch model (air cooled or water
2) Opening the gun trigger ends the welding cooled) being used.
sequence (burnback, postflow, etc.
M3. Cold inch control and gas purge
With Crater Fill “ON”: control.
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This is an up/down center-off momentary adjustments will be made to the preset arc
toggle switch. lengths, and is optimum for most conditions. An
When held in the down position, the Wire LED lights to inform the user which function (volts
Drive will feed wire, but neither the power or trim) is active.
source nor the gas solenoid will be energized. Both displays indicate preset values, according to the
When cold feeding, the feed speed can be weld mode selected, when not welding. Once welding
adjusted by rotating the WFS encoder knob begins, they switch to displaying actual values. At that
on the Control Box. Adjusting the cold feed time, the indicator LEDs will flash to signify actual
values are being displayed. The displays hold the actual
will not affect the run in or welding wire feed values for 5 seconds after a weld is stopped. Turning a
speed. When the cold feed switch is released, knob during the hold time shuts off the hold, and returns
the cold feed value is saved. the meters to their preset values.
When this switch is held in the up position, the gas

solenoid valve is energized, but neither the power
source nor the drive motor will be energized. MSP3 Panel
Control Panels
Control/Display Front Panel.
This panel provides a selection of over 30 weld modes,

including CV, pulse FCAW and CC, through a toggle
switch and indicator lights (LEDs). It allows for
adjustment of all set up parameters, Preflow, Run In,
Arc Control, Burnback, Postflow, and Crater, through an
up/down toggle switch, indicator lights and a 3 digit
display.
To adjust a set up parameter (Weld Mode being

one of those parameters), first select one of the
This panel consists of adjustment knobs, digital set up parameters for adjustment, and then adjust
displays and a series of indicator lights (LEDs). the displayed value up or down.
There are two knobs; each has a 4 digit LED Set up parameters are selected with the SELECT
display and a pair of LEDs associated with it. switch, an up/down center-off momentary toggle
Knobs and displays have dual functions; the LEDs switch.
indicate which function at any given time. Moving the switch bat up or down moves an LED
The left knob/display is labeled WFS / AMPS (wire in the corresponding direction. Holding the switch
feed speed/amps). in either direction will cause the indicator to move
- In non-synergic modes, the WFS control quickly in the corresponding direction until the
changes the wire feed speed according to the switch is released, or the upper or lower limit is
desired procedure. reached.
- In synergic welding modes (synergic CV, pulse The value of the active set up parameter is shown
GMAW) WFS is the dominant control parameter, on the panel digital display. The value can be
controlling all other variables. modified with the SET switch. The SET switch is
The power source then uses the WFS setting to an up/down center-off momentary toggle switch.
adjust its output characteristics (output voltage, Moving the switch bat up or down adjusts the
output current) according to preprogrammed displayed value in the corresponding direction.
settings contained in the power source. Holding the switch in either direction will cause the
A LED lights to inform the user which function display to move quickly in the corresponding
(WFS or amps) is active. direction until the switch is released, or the upper
The right knob/display is labeled VOLTS / TRIM. or lower parameter limit is reached.
In constant voltage modes (synergic CV, standard
CV) the control adjusts the welding voltage.
In pulse synergic welding modes (pulse GMAW Weld Mode
only) the user can change the Trim setting to The Weld Mode selection can be enabled by toggling
adjust the arc length. It is adjustable from 0.50 to the SELECT switch until the LED next to WELD MODE
1.50. A Trim setting of 1.00 means than no is lit. The present mode number will be displayed.
14
Positioning the SET switch up or down will
increase or decrease to the next WELD MODE
number and display it. The machine will change to Start
the selected weld mode after two seconds of SET • The Start function offers the ability to set a wire
switch inactivity. If the SELECT switch is changed feed speed and voltage at the beginning of a weld
before two seconds of SET switch inactivity, the for a specified time period of the weld prior to
machine will not change modes. The last active initiation of the preset values for WFS and Volts.
Weld Mode will be saved at power down so that it At arc strike, the start timer will begin and the
will be selected upon the next power up of the WFS and Volts settings will ramp up/down from
machine. the start values to the Weld Mode WFS and
Voltage settings over the time selected. This
creates a ramping of the WFS and Volts during
Preflow / Postflow
the Start time.
• The Preflow setting allows a time to be selected • The Start function will be selected by toggling
for shielding gas to flow after the trigger is pulled the SELECT switch until the LED next to START
and prior to wire feeding and arc strike. is lit and flashing. A start time may be adjusted
• The Postflow setting allows a time to be selected using the SET switch.
for shielding gas to continue to flow after the • The default value is "OFF" (0 seconds).
trigger is released and output current is turned off. • Start time is adjustable from 0 to 0.50 seconds in
• The Preflow timer will be selected by toggling the .01 second increments.
SELECT switch until the LED next to PREFLOW / • In the GMAW, FCAW, and Power weld modes,
POSTFLOW is lit. The Display Meters will read start wfs and voltage are adjustable using the
PrE FLo. The present Preflow time will be control knobs on the upper case front. This is
displayed and can be changed by positioning the indicated by the flashing LEDs next to "WFS" and
SET switch up or down. "VOLTS."
• The Postflow timer will be selected by toggling • In the GMAW-P weld modes, a start wire feed
the SELECT switch and additional time. The LED speed and trim are adjustable. This is indicated by
next to PREFLOW / POSTFLOW will remain lit; the flashing LEDs next to "WFS" and "TRIM."
but the Display Meters will now read PoS FLo.
The present Postflow time will be displayed and
can be changed by positioning the SET switch up Arc Control
or down. • In the CV modes, the Arc Control regulates
• The default value for both Preflow and Postflow pinch effect. At the minimum setting, pinch is
is "OFF" (0 seconds). minimized which results in a soft arc. Low pinch
• Preflow can be adjusted from 0 to 2.5 seconds in settings are preferable for welding with gas mixes
0.1 second increments. containing mostly inert gases. At the maximum
• Postflow can be adjusted from 0 to 10.0 seconds setting, pinch is maximized which results in a crisp
in 0.1 second increments. arc. High pinch settings are preferable for welding
FCAW and GMAW with CO2. Most self-shielded
wires work well at an Arc Control setting of 5.
Run-In
• In the Pulse Mode, the Arc control regulates the
• The Run-In function offers the ability to set a frequency of the pulse.
wire feed speed, from trigger until an arc is • In the Pulse & Pulse Mode, the Arc Control
established, that is independent of the Welding or regulates the frequency of oscillations between
Start wire feed speed. high and low level of amperage.
• Run-In will be selected by toggling the SELECT • In the CC-Stick modes, the Arc Control regulates
switch until the LED next to RUN-IN is lit. A Run- the Arc Force to adjust the short circuit current.
In WFS may be adjusted using the SET switch on The minimum setting will produce a soft arc and
the Multi-Process Panel. The Display meter on the will result in minimal spatter. The maximum
Multi-Process Panel will indicate the run-in speed. setting will produce a crisp arc and will minimize
Do not use the Output Control Knob on the electrode sticking.
uppercase front to adjust the WFS. This will • The Arc-control adjustment will be selected by
change the welding WFS displayed in the meters toggling the SELECT switch until the LED next to
on the upper case front. ARC CONTROL is lit. The Arc-control value will
• The default value is "OFF." be displayed. Arc-control can be adjusted by
• Run-In speed is adjustable from 1.27m/min to positioning the SET switch up or down.
3.81m/min. • The default value is "OFF."
• The value is adjustable from –10.0 to 10.0 in 0.1
increments.
15
Crater The following table summarizes the action taken
• The Crater function offers the ability to set an when the user exits the memory mode:
endpoint for WFS and Voltage that will be reached MSP3 Action taken when the user uses
over a specified time period. At the end of the display the SELECT switch to exit the
weld when the trigger is released, the crater timer MEMORY mode
will begin and the WFS and Volts settings will “S-8” Save to user memory #8
ramp down from the Weld Mode WFS and … …
Voltage settings to the Crater WFS and Voltage “S-2” Save to user memory #2
settings over the time selected. This creates a “S-1” Save to user memory #1
ramp down of the WFS and Volts during the “---“ No action (default display each
Crater time. time memory mode is entered) or
• The Crater timer will be selected by toggling the exit for machines code 54000
SELECT switch until the LED next to CRATER is and above
lit and flashing. A crater time may be adjusted “r-1” Recall from user memory #1
using the SET switch. “r-2” Recall from user memory #2
• The default value is "OFF" (0 seconds). … …
• Crater time is adjustable from 0 to 10.0 seconds “r-8” Recall from user memory #8
in .1 second increments. When a memory save or memory recall is
• In the GMAW, FCAW, and Power weld modes, performed, the MSP3 panel will briefly scroll a text
crater WFS and voltage are adjustable using the message to indicate that an action occurred.
control knobs on the upper case front. This in When a memory saved is performed, “SavEd” will
indicated by the flashing LED’s next to "WFS" and be displayed. When a memory recall is performed,
"VOLTS." “rEcALLEd” will be displayed. When the memory
• In the GMAW-P weld modes, Crater WFS and mode is exited when the four dashes are
trim are adjustable. This is indicated by the displayed, there is no additional text displayed on
flashing LEDs next to "WFS" and "TRIM." the MSP3 on machines code below 54000. For
machines code 54000 and above, the display
stays on "r-1" or "s-1" to show the memory
Burnback position.
• The Burnback feature will allow current to If the user attempts to restore from memory
continue to flow for a specified time period at the location that was not previously saved, the
end of a weld after wire feeding has stopped. memory mode will exit without scrolling the
• The Burnback timer will be selected by toggling “rEcALLEd” message as an indication that no
the SELECT switch until the LED next to action occurred.
BURNBACK is lit. A burnback time may be There will be no timeout time associated with
adjusted using the SET switch. memory saving and recalling. The user must exit
• The default value is "OFF" (0 seconds). the memory mode using the SELECT switch.
• Burnback time is adjustable from 0 to 0.25 seconds in
0.01 second increments.
Pulse & Pulse Welding Mode
Memory - Functional Specification On this machine, Lincoln has introduced the
possibility to weld with "Pulse-on-Pulse" MIG
The memory mode is entered when the MEMORY process for aluminium.
LED is illuminated and exited when the MEMORY Pulse-on-Pulse uses a modification of the Pulsed
LED is extinguished using the SELECT switch. MIG process where the output is quickly switched
Each time the MEMORY LED is selected using between a Low-Energy Pulse procedure and a
the SELECT switch, the display on the MSP3 will High-Energy Pulse procedure.
show four dashes “----“ to indicate that no action
will occur if the user exits the MEMORY mode by
using the SELECT switch.
If the SET switch is pushed up, the four dashes
will change to “S-1” to indicate that the present
weld mode and associated parameters will be
Saved to user memory #1 when the SELECT
switch is used to exit the memory mode.
Pressing the SET switch down past the four
dashes will cause the display to change to “r-1” to
indicate that the weld mode and associated
parameters currently stored in user memory #1
will be recalled when the SELECT switch is used
to exit the memory mode.
16
Advantages : " Good penetration profileLess short circuit
" Wider operating range, ability to weld thinner disturbancesThe High-Energy pulse cleans the
materials base metal and improves arc stability
" Less demanding in terms of wire placement, travel " Pulse-on-Pulse provides "stacked dime" weld bead
speed and parameter adjustment appearance making the weld more uniform in
" High travel speed without lack of fill imperfections appearance
" Good bead wetting, less undercut, flatter weld bead
17
ACCESSORIES
K10343 Adapter for Innershieldpistol
K10353-2 Remote control box

.
K10391-00-8M Push-pull Torch, water cooled, 8 meters (Straight "00" or 45° "45" goose neck)
And K10391-45-8M
Drive rolls and guide tubes 2 driven rolls
Solid wires
KP10344-0.8 0,6-0,8MM
KP10344-1.0 0,8-1,0MM
KP10344-1.2 1,0-1,2MM
KP10344-1.6 1,2-1,6MM
Cored wires
KP10344-1.6C 1.0-1.6mm
Aluminum wires
KP10344-1.2A 1,0-1,2MM
KP10344-1.6A 1,2-1,6MM
Drive rolls and guide tubes 2 driven rolls
Solid wires
KP10344-0.8 0,6-0,8MM
KP10344-1.0 0,8-1,0MM
KP10344-1.2 1,0-1,2MM
KP10344-1.6 1,2-1,6MM
Cored wires
KP10344-1.6C 1.0-1.6mm
Aluminum wires
KP10344-1.2A 1,0-1,2MM
KP10344-1.6A 1,2-1,6MM
K10363-1 2-pinion kit for KP10344, configuration 4-roll drive
K10362-1 2-idle roll kit for KP10344, 2-roll drive configuration
18
MAINTENANCE
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this maintenance.• Turn the input power
OFF at the disconnect switch or fuse box before working
on this equipment.
• Do not touch electrically hot parts.
ROUTINE AND PERIODIC MAINTENANCE

To avoid receiving an electric shock, keep electrode holders and cable insulation in good condition.
1. Disconnect power supply lines to the machine before performing periodic maintenance.
2. In extremely dusty locations, dirt may clog the air channels, causing the welder to run hot.
Periodically blow out dust and dirt from the inside of the machine with a low pressure air system. Be
sure to clean the following components thoroughly. See Figure D.1 for their location.
• Main transformer
• Output studs
• Polarity switch
• Rectifier assembly
• Control box assembly
3. Dirt and dust may also accumulate on the remote control terminal strips. Wipe or blow off the
terminal strips regularly, especially in damp locations.
4. Inspect the welder output terminals and control cables for fraying, cuts, and bare spots.
5. The fan motor has sealed ball bearings and requires no maintenance.
MAJOR COMPONENT LOCATIONS
19
MAINTENANCE
BASE EXPLODED VIEW
For Machines CODE 5025 and above
item Part number Description Qty

1A G10376-1 Base 1
1B L50642-1 Low bottle mounting plate 1
2 S51590-4 Rear wheel 2
S51238 Cap 2
S51378-4 Axle 1
3 S51600-2 Front wheel 2
4 M51595-1 Top baffle 1
M51594-1 Left baffle 1
M51593-1 Right baffle 1
5 L50773-1 Transformer 230V / 400V 1
6 M51573 PFC choke 1
7 M19555 Chopper choke 1
8 L11132-3 Diode bridge 1
M51590-1 Diode bridge bracket 1
9 S52093 EMC filter low voltage 1
10 S51882-1 Flow meter 1
11 L11947 Chopper 1
M51574-4 Left chopper bracket 1
M51574-3 Right chopper bracket 1
T13359-13 Thermostat 1
20
MAINTENANCE

12 M51627-1 Front panel 1
13 M51619 Handle bracket 1
14 M51551-1 Handle 1
15 S19664 Quick connector female 1
S19663 Quick connector male 1
M18021 Quick connector mounting plate 1
16 M51621 Euro-connector bracket 1
17 T10491 Potentiometer knob 2
18 T50646-1 1/4 turn stud connector 1
19 S12021-3 Amphenol plug 1
20 M51012-2 Commutator 1
21 T10800-49 SET / SELECT switch 2
S22061-1 Switch cap 2
22 S52090-1 Status led board 1
23 M19790-2 MSP3 selection board 1
24 M17789-3 Encoder 2
25 L11130-3 Display board 1
26 S17062-2 Cable connector cap 1
27 S52105 Protection switch 2
21
MAINTENANCE
GENERAL EXPLODED VIEW
22
MAINTENANCE

26 L50762-1 Rear panel 1
L50804 Case plate assembly 1
M51390-1 Bottle mounting plate high 1
T50227 Gas bottle chain 1
S51737-4 Cable clamp 1
S51036 220V female plug 1
T12287-2 Circuit breaker 3,5 A 1
M51206-1 Gas solenoid 12V 1
S51632 Gas connector 1
M51502-2 Fan 1
M51501 Fan bracket 1
27 M51572 Feeding plate 1
M51518 Wire feeder motor 1
S18011-1 Ring magnet 1
S18012 Tachometer sensor 1
S51887 Tachometer cover 1
See FP1050-D See part list
28 L50769-1 Middle panel 1
M51199 Axle 1
S10433-1 Fuse holder 2
S51408 Static relay 1
S52094 EMC filter welding 1
T10728-20 Fuse 2A 1
T10728-26 Fusie 5A 1
T10800-4 Air / Water switch 1
T10800-49 Gas purge / Cold inch switch 1
T13562 2T / 4T switch 1
29 L50767-1 Right separate panel 1
M13900 Output terminal 2
S18504-2 Current transducer 1
30 L50768-1 Left separate panel 1
M51579 Filter board 1
M52000 Filter board choke 1
S51661-1 Reconnect panel 1
S51991-10 Capacitor 1
G3632-2 Digital power supply 1
31 M51569-1 Board protection panel 1
Contact spare parts Control board 1
Contact spare parts Feeder board 1
32 M51571-1 Separate panel 1
33 G3526 Tools tray 1
34 M51634 Roof and hinges assembly 1
35 L50772-1 Upper bar 1
36 L50770-1 Left door 1
37 L50771-1 Rignt door 1
38 M51620-1 Reconnect panel access door 1
39 L50764-1 Rignt panel 1
40 L50765 Left panel 1
G10381 Left and right decal 1
41 K10158-1 Readi-reel adapter 1
Non M50758-90 Input cable 1
illustrated
M51183-140-3 Harness 1
G10380 Nameplate 1
23
THEORY of OPERATION
General Description
The PW345C is a complete semiautomatic, multi-process DC arc welding machine offering CV and
CC DC welding. It is rated for 345 amps, 32 volts, at 35% duty cycle for 208. The standard machine is
equipped to weld CC Stick, CC-GTAW, CV-FCAW, and synergic and non-synergic CV
GMAW/GMAW-P, Pulse-on-Pulse, and Power Mode welding processes. The digital microcomputer
based control system allows easy and accurate adjustment of weld parameters through the multi-
process panel located on the front of the machine. The PW345C is equipped with a 6-pin connector for
a foot amptrol or remotes and a 3-pin connector to allow operation of a push-pull gun for feeding
aluminum wires.
24
THEORY of OPERATION
Input Line Voltage and Main Transformer
Three-phase input power is brought into the rear of the. A reconnect panel, also located on the rear of
the machine, allows the user to configure the PW345C for either 230V or 400V input supply power.
An ON/OFF line switch is located on the front panel. When the line switch is ON, AC input voltage is
applied to the primary winding of the main transformer. The main transformer converts the high
voltage, low current input power to a low voltage, high current output. The main transformer also has
two isolated auxiliary windings. One supplies 30 VAC to a Diode Control Rectifier, which converts the
30 VAC to 40 VDC to supply the Power Board and the Spool Gun Board. The Power Board in turn
supplies 20VDC to the Chopper Board and +15 VDC, -15 VDC and+5 VDC to the Weld Control Board
circuitry. The other auxiliary winding provides 115 VAC to operate a thermostatically controlled fan
motor through a relay, which also receives signals from the Weld Control Board. The fan is designed
to come on automatically when the trigger is pulled. The fan will stay on as needed for a minimum of
six minutes after the weld arc is terminated. The fan will also stay on when the machine's welding and
feeding are disabled during thermostatic over-temperature protection. (See Thermal and Overload
Protection.)
25
THEORY of OPERATION
Input Rectifier, Chopper Assembly and Feedback
The 60 VAC output from the main transformer secondary is connected to an input rectifier. The
resultant 80 VDC is applied to four parallel capacitors incorporated within the Chopper Assembly.
These capacitors function as filters and also as power supplies for the insulated gate bipolar
transistors or IGBT. See IGBT Operation in this section. The IGBT acts as a high speed switch
operating at 20KHZ. This device is switched on and off by the Weld Control Board through pulse width
modulation circuitry. See Pulse Width Modulation in this section. This "chopped" DC output is
applied through an output choke coil to the negative output terminal and through a current transformer
to the positive output terminal. The choke functions as a current filter. A free-wheeling diode is
incorporated in the Chopper Assembly to provide a current path for the stored energy in the choke
when the IGBT is turned off. See Chopper Technology Fundamentals in this section. Output voltage
and current feedback information is fed to the Weld Control Board. This information is sensed from the
current transformer and voltage sense circuitry on the output terminal circuits. If current or voltage
become abnormally high, the Weld Control Board will shut off the IGBT’s, thus disabling the machine's
output.
26
THEORY of OPERATION
Diode Control Rectifier and Power Board
The Power Board receives approximately 40 VDC from the Diode Control Rectifier. In turn, the Power
Board supplies a variety of regulated DC voltages to the Weld Control Board, which it uses to power
its many circuits and communication functions. The Power Board also supplies +20 VDC to the
Chopper Assembly.
27
THEORY of OPERATION
Weld Control Board
The Weld Control Board performs the primary interfacing functions to establish and maintain output
control of the Power Wave 345C machine. The function generator and weld files reside within the
Weld Control Board hardware and software. Digital command signals and feedback information from
other machine components are received and processed at the Weld Control Board. Software within
the Weld Control Board processes the command and feedback information and sends the appropriate
pulse width modulation (PWM) signals to the Chopper Assembly IGBT. (See Pulse Width Modulation
in this section). In this manner, a digitally controlled high-speed welding waveform is created.
In addition, the Weld Control Board monitors the Chopper thermostat and the Main Transformer
secondary winding thermostat, the Main Transformer primary winding currents and input filter
capacitor voltages. In the event of a fault condition, the Weld Control Board will activate the thermal
and/or the status light and will disable or reduce the machine output.
28
THEORY of OPERATION
Wire drive motor and feedback
The wire drive motor is controlled by the feeder board and the weld control board. A motor speed
feedback signal is generated at the motor tachometer and sent to the feeder board, which compares
this feedback signal to the commands from the encoder board. It then sends the appropriate armature
voltage to the wire drive motor. This controlled wire drive speed in turn regulates the electrode wire
feed speed through the gun.
29
THEORY of OPERATION
Thermal Protection
Two normally closed (NC) thermostats protect the machine from excessive operating temperatures.
These thermostats are wired in series and are connected to the Weld Control board. One of the
thermostats is located on the Chopper Assembly board and one is on the secondary of the Main
Transformer. Excessive temperatures may be caused by a lack of cooling air or by operating the
machine beyond its duty circle or output rating. If excessive operating temperatures should occur, the
thermostats will prevent output from the machine. The yellow thermal light, located on the front of the
machine, will be illuminated. The thermostats are self-resetting once the machine cools sufficiently. If
the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating
normally, the power switch may be left on and the reset should occur within a 15-minute period. If the
fan is not turning or the intake air louvers are obstructed, the power must be removed from the
machine and the fan condition or air obstruction corrected. The cooling fan runs only when necessary.
The FAN (fan as needed) system is controlled by the Weld Control Board via the solid state relay.
Over Current Protection
If the average current exceeds 345 to 350 amps, the peak current will be limited to 100 amps until the
system is re-triggered or the average current decreases to under 50 amps.
Wire Feeder Overload Protection
The Power Wave 345C wire drive motor has its own solid state overload protection. If the motor
becomes overloaded, the protection circuit turns off the wire feed and the gas solenoid. Overload may
result from improperly sized tip liner and drive rolls, obstructions or bends in the gun cable, and any
other factors that would impede the wire feeding. To resume welding, simply pull the gun trigger.
There is no circuit breaker to reset, as the protection is provided by reliable solid state electronics.
30
THEORY of OPERATION
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconduc- tors well suited for high frequency
switching and high current applications.
Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to
the source, and therefore, no current flow.The drain terminal of the IGBT may be connected to a
voltage supply; but since there is no conduction the circuit will not supply current to components
connected to the source. The circuit is turned off like a light switch in the OFF position.
Drawing B shows the IGBT in an active mode. When the gate signal, a positive DC voltage
relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A
voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to
circuit components coupled to the source. Current will flow through the conducting IGBT to
downstream components as long as the positive gate signal is present. This is similar to turning ON a
light switch.
31
THEORY of OPERATION
Pulse width Modulation
The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction
in the positive and negative portions of the cycle. Changing the pulse width is known as
32
MODULATION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed
range of a cycle to affect the output of the machine.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT is turned on and off for different duration’s
during a cycle. The top drawing below shows the minimum output signal possible over a 50-
microsecond time period. The positive portion of the signal represents one IGBT group conducting for
1 microsecond. The negative portion is the other IGBT group. The dwell time (off time) is 48
microseconds (both IGBT groups off). Since only 2 microseconds of the 50-microsecond time period
are devoted to conducting, the output power is minimized.
MAXIMUM OUTPUT
By holding the gate signals on for 48 microseconds each and allowing only 2 microseconds of dwell
time (off time) during the 50-microsecond cycle, the output is maximized. The darkened area under the
top curve can be compared to the area under the bottom curve. The more dark area under the curve,
the more power is present.
33
THEORY of OPERATION
Chopper Technology Fundamentals
The new era of welding machines such as the Power MIG 300 employ a technology whereby a DC
source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control
an arc. Hence the name “Chopper.” The biggest advantage of chopper technology is the high-speed
control of the arc, similar to the inverter machines. A block diagram for this is as follows:
34
In this system, the engine drives a three-phase alternator, which generates power that is rectified and
filtered to produce about 80VDC. The current is applied through a solid state switch to an inductor. By
turning the switch on and off, current in the inductor and the arc can be controlled. The following
diagram depicts the current flow in the system when the switch is open and closed:
When the switch is closed, current is applied through the inductor to the arc. When the switch opens,
current stored in the inductor sustains flow in the arc and through the diode. The repetition rate of
switch closure is 20Khz, which allows ultra-fast control of the arc. By varying the ratio of on time
versus off time of the switch (Duty Cycle), the current applied to the arc is controlled. This is the basis
for Chopper Technology: Controlling the switch in such a way as to produce superior welding.
35
TROUBLESHOOTING & REPAIR
How to use troubleshooting guide
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 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.
This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM”
(SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the
listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into two
main categories: Output Problems and Welding Problems.
Step 2. PERFORM EXTERNAL TESTS. The second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external possibilities that may contribute to the machine
symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted
without removing the case cover.
Step 3. PERFORM COMPONENT TESTS. The last column, labelled “Recommended Course of
Action” lists the most likely components that may have failed in your machine. It also specifies the
appropriate test procedure to verify that the subject component is either good or bad. If there are a
number of possible components, check the components in the order listed to eliminate one possibility
at a time until you locate the cause of your problem
All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at
the end of this section. Refer to the Troubleshooting and Repair Table of Contents to locate each
specific Test Procedure. All of the referred to test points, components, terminal strips, etc. can be
found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams
Section Table of Contents to locate the appropriate diagram.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed.
36
PC Board Troubleshooting Procedures
Have an electrician install and service this equipment. Turn the machine OFF
before working on equipment. Do not touch electrically hot parts.
Sometimes machine failures appear to be due to PC board failures. These problems can sometimes
be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC
boards,please use the following procedure:
1. Determine to the best of your technical ability that the PC board is the most likely component
causing the failure symptom.
2. Check for loose connections at the PC board to assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC board using standard practices to avoid static
electrical damage and electrical shock. Read the warning inside the static resistant bag and perform
the following procedures:
PC Board can be damaged by static electricity.
• Remove your body’s static charge before opening the static-shielding bag.
Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord
connected to a grounded part of the equipment frame.
• If you don’t have a wrist strap, touch an unpainted, grounded, part of the
equipment frame. Keep touching the frame to prevent static build-up. Be sure
not to touch any electrically live parts at the same time.
• Tools which come in contact with the PC Board must be either conductive,
anti-static or static-dissipative.
• Remove the PC Board from the static-shielding bag and place it directly into
the equipment. Don’t set the PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board can’t be installed immediately, put
it back in the static-shielding bag.
• If the PC Board uses protective shorting jumpers, don’t remove them until
installation is complete.
• 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
proper failure analysis.
4. Test the machine to determine if the failure symptom has been corrected by
the replacement PC board.
NOTE: Allow the machine to heat up so that all electrical components can reach their operating
temperature.
5. Remove the replacement PC board and substitute it with the original PC board to recreate the
original problem.
a. If the original problem does not reappear by substituting the original board, then the
PC board was not the problem. Continue to look for bad connections in the control wiring
harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the substitution of the original board, then the PC
board was the problem. Reinstall the replacement PC board and test the machine.
6. Always indicate that this procedure was followed when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED
PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.
37
TROUBLESHOOTING GUIDE
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTEMENTS COURSE OF ACTION
Major physical or electrical damage 1. Contact your local authorized

is evident when the sheet metal Lincoln Electric Field Service Facility
cover(s) are removed for technical assistance
Machine is dead - no welding output 1. Make certain that the input power USE MACHINE SCHEMATIC
and no wire feed when gun trigger is switch is in the "ON" position. 1. Check for approximately 80VDC
pulled. 2. Check the input voltage at the at output of rectifier. If 80VDC is
machine. Input voltage must match present go to step (3).
the rating plate and the reconnect
panel. 2. Check for the presence of input
3. Blown or missing fuses in the voltage at the reconnect panel (H1,
input line. H4). If voltage is still not present,
4. Check for thermal light on case check for the presence of input
front. Thermostats may be open due voltage at (L1, L2) at the reconnect
to machine verheating. If machine panel. If good check the leads for
operates normally after a cooling off bad connections between reconnect
period then check for proper fan panel and line switch. If ok, change
operation and ventilation. Make Line switch (S1).
certain that the machine’s duty cycle
is not being exceeded. 3. Check for Red LED 1 & LED 2 on
5. Remove the gun trigger Digital Power Supply PC Board. If
connection and jump the two LED’s are not on, check for
connections at the machine. If you approximately 42VDC at leads
have a wirefeed gun, it may be 2J41(472) and 1J41 (471).
faulty. Replace. If voltage is not present Perform
Control Rectifier Test. If voltage is
present jump out trigger lead at
Feed Head PCB leads 1J85 (851)
and 2J85 (852). If you have output
or wire feed check wiring back to the
trigger amphenol on the center
panel. If not check for 42 volts at
leads 3J82 (3243) and 4J82 (3244)
If voltage is present Feed Head
board may be faulty, Replace.
No welding output but wire feeds 1. Check the input voltage at the 1.
normally when gun trigger is pulled. machine. Input voltage must match
the rating plate and the reconnect
panel.
2. The gun may be faulty. Check for
continuity.
3. Check continuity through the work
lead.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
38
No welding output but wire feeds 1. Check the input voltage at the 1. Check for loose or broken
normally when gun trigger is pulled. machine. Input voltage must match connections at the output terminals,
the rating plate and the reconnect the choke and all heavy current
panel. carrying leads. See the Machine
2. The gun may be faulty. Check for Schematic.
continuity. 2. Make sure that the transformer
3. Check continuity through the work secondary leads are securely
lead. connected to the Output Rectifier
assembly.
3. Check for OCV at output studs
when trigger is pulled. If OCV is
present, the gun may be
faulty.Replace.
4. Check for 57VAC at the input of
output rectifier. If reading is not
correct Perform Main Transformer
Tests. If you measure
approximately 57 VAC, check for
80VDC at the output of the output
rectifier. If reading is not correct
Perform the output Rectifier
Assembly Tests. If 80VDC is there
Perform Chopper Board Test.
5. Check for 15VDC input to the
Control Board at leads 12J4 (412) to
10J4 (410), -15VDC at leads 11J4
(411) to 10J4 (410), 5VDC at leads
8J4 (408) to 10J4 (410). If missing a
voltage check wiring back to Digital
Power Supply PCB. If voltage is ok,
the Control Board may be faulty.
Replace.
Wire feeds but welding output is 1. Make sure that the proper wire 1. Check for loose or faulty
low causing wire to “stub”. Welds and procedures are being used. connections of the heavy current
are “cold”. Machine cannot obtain 2. Check gun and work cable for carrying leads.
full rated output of 300 amps at 32 loose or faulty connections. 2. Perform the Current Transducer
volts. Test.
3. Perform Output Waveform Test.
4. Perform the Output Rectifier
Assembly Tests
5. The Control Board may be faulty.
Replace.
The output voltage and wire feed is 1. Remove the gun. If the problem is 1. Find J85 on Feed Head Board
present continuously or pulsing resolved, the gun trigger circuit is and unplug. If the problem still exist
when gun trigger is NOT activated. faulty. Repair or replace. Feed Head Board may be faulty.
2. If problem persists when gun
assembly is removed from machine,
then the problem is within the
PW345C
39
No control of arc voltage. Wire 1. The arc voltage encoder may 1. The arc voltage encoder may
feeding is normal. be dirty. Rotate several times be faulty. Codes 10562 have
and check if problem is resolved. both Encoders on one board.
Codes above 10562 have single
Encoders.
2. If machine has code 10562 or
lower change Encoder Board. If
machine has Code above 10562
Perform Encoder Test.
3. The Feedhead board may be
faulty. Replace.
There is no gas flow when gun 1. Check gas source and hoses 1. Check for 6.5 VDC when
trigger is pulled. Wire feeds and for leaks or kinks. trigger is pulled at feedhead
weld voltage is present. 2. Check regulator on the tank Board, Plug J83-3 lead 833
for the pressure being set to and J83-4 lead 834.
high. If you read 12 VDC solenoid
may be open or a bad
connection. Check wiring. Check
the gas solenoid by
disconnecting it from the Feeder
Board (Plug J83-3 & 4) and
applying a 12 VDC external
supply to the gas solenoid. If the
solenoid does NOT activate then
it may be faulty. Replace.
2. If 6.5VDc is not present the
Feeder broad may be faulty.
Replace.
The machine stops feeding wire 1. Check for adequate wire 1. Check the motor armature
while welding. supply. current. Normal armature current
2. Check for mechanical is 2.0 to 2.7 amps maximum. If
restrictions in the wire feeding the motor armature current is
path. The gun may be clogged. normal the Feeder Board may
3. Check gun liner and tip are be faulty. Replace.
correct for wire size being used. 2. If the motor armature current
4. Check spindle for ease of is high (over 2.7 amps) and
rotation. there are NO restrictions in the
5. Check to see if the spot timer wire feeding path then the motor
has been activated. or gear box may be defective.
Replace.
40

No control of wire feed speed. Other 1. The wire feed speed encoder 1. Perform the Wire Drive Motor
machine functions are normal. control may be dirty. Rotate several and Tachometer Feedback Test.
times and check if problem is 2. The Wire Speed Encoder may be
resolved. faulty. If code is 10562 or below
change Encoder PCB. If code is
above 10562 Perform Encoder
Test
3. The Feeder Head Board may be
faulty. Replace.
There is no wire feed when gun 1. Check for wire jam at drive rolls. 1. Perform the Wire Drive Motor and
trigger is pulled. Normal open circuit 2. If the drive rolls are turning then Tachometer Feedback Test. 2.The
voltage is present. check for a mechanical restriction in Wire Speed Control Encoder may
the wire feed path. be faulty. If code is 10562 and below
3. The gun liner may be clogged. change Encoder PCB. If code is
Check or replace. above 10562 Perform Encoder Test
3. The Feeder Head Board may be
faulty. Replace.
The arc is unstable and or “hunting.” 1. Check for worn or melted contact 1. Check for loose connections at
tip. the output terminals, the chokes,
2. Check for loose or faulty and all heavy current carrying leads.
connections on the work and See the Machine Diagram.
electrode cables. 2. Make sure that the transformer
3. Make sure electrode polarity or secondary leads are securely
welding process being used is connected to the Output Rectifier
correct. assembly.
4. Check for rusty or dirty wire. 3. Perform the OCV and Output
5. Make sure machine settings are Voltage Wave Test. If waveforms
correct for process being used. are not correct Perform the Output
(shielding gas, wire type, wire size). Rectifier Assembly Tests.
4. Reload latest software. Contact a
Lincoln Electric sales representative
for latest software.
5. The Control board may be faulty.
Replace.
The contact tip seizes in the gas 1. The tip being over heated due to
diffuser. excessive current and/or high duty
cycle welding.
2. A light application of high
temperature anti-seize lubricant
(such as Lincoln E2607 Graphite
Grease) may be applied to the
contact tip threads.
Weld bead is narrow or ropy. May 1. Make sure the weld procedure 1. Perform the OCV and Output
have porosity with electrode and electrode polarity is correct for Voltage Wave Test. If waveforms
stubbing into plate. the process being used. Welding are not correct Perform the Output
voltage may be too low for wire feed Rectifier Assembly Tests.
speed being used. 2. Reload latest software. Contact a
2. Make sure shielding gas is correct Lincoln Electric sales representative
and flow is proper. for latest software.
3. Make sure the weld joint is not 3. The Control board may be faulty.
“contaminated”. Replace.
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed
41

The welding arc is variable and 1. Check the welding cable 1. Perform the OCV and Output
sluggish. connections for loose or faulty Voltage Wave From Test. If
connections. waveforms are not correct
2. Make sure the wire feed Perform the Output Rectifier
speed, voltage, and shielding Assembly Tests.
gas are correct for the process 2. Reload latest software from a
being used. Lincoln Electric sales
representative
3. The Control Board may be
faulty. Replace.
The arc striking is poor. 1. Check the welding cable 1. Perform the OCV and Output
connections for loose or faulty Voltage Wave Test. If
connections. waveforms are not correct
2. Make sure the wire feed Perform the Output Rectifier
speed, voltage, and shielding Assembly Tests.
gas are correct for the process 2. Reload latest software from a
being used. Lincoln Electric sales
3. Run in settings may need to representative
be adjusted. 3. The Control board may be
faulty. Replace.
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed
42
CHOPPER BOARD CAPACITOR DISCHARGE PROCEDURE
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. If for any reason you do not
understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln
Electric Service Department for electrical troubleshooting assistance before you proceed.
DESCRIPTION
This procedure will insure that the five large capacitors on the Chopper Board have been discharged.
This procedure should be performed whenever work is to be attempted on or near the Chopper Board.
MATERIALS NEEDED
Nutdriver
Volt/Ohmmeter
Resistor (25 ohms and 25 watts minimum)
Jumper leads
Wiring Diagram
43
CHOPPER BOARD CAPACITOR DISCHARGE PROCEDURE
PROCEDURE

High voltage is present when input power is applied to the machine.
Refer to Figure F.1.

1. Remove main input power supply to the machine.
2. Lift the hinged right side case cover.
3. Using the 3/8 in. nutdriver, remove the bottom right case cover.
4. Locate the Chopper Board with capacitors mounted on the center of the machine base, right side.
See Figure F.1.
5. Using the resistor and jumper leads, CAREFULLY discharge the capacitor terminals. There are 5
capacitors. NEVER USE A SHORTING STRAP FOR THIS PURPOSE. DO NOT TOUCH THE
TERMINALS WITH YOUR BARE HANDS. [ NEED THIS PROCEDURE VERIFIED ] To discharge the
capacitors, hold the jumper leads to the following terminals for a minimum of 10 seconds each. See
Figure F.1 and the Wiring Diagram.
Capacitors Terminals
C1, C2, C3 and C4 B1 and B2
C5 B1 and B5
6. Using the volt/ohmmeter, check the voltage across terminals B1 and B2 and B1 and B5 (as in step
5). Each reading should now be zero volts.
44
Main Transformer voltage Test
you proceed.
DESCRIPTION
This test will determine if the correct voltages are being applied to the primary windings of the main
transformer and induced on the secondary and auxiliary windings.
MATERIALS NEEDED
Nutdriver
Volt/Ohmmeter
45
Main Transformer voltage Test
PROCEDURE
85 Vdc
60 VAC
The ON/OFF POWER SWITCH will be "hot" during these tests.
NOTE: Secondary voltages will vary proportionately with the primary input voltage.
1. Disconnect the main input power supply to the machine.
TEST NAMEPLATE INPUT VOLTAGE TO THE MAIN TRANSFORMER PRIMARY WINDING:
2. Confirm the reconnect panel is connected properly for the correct voltage. See reconnect panel
connection diagram located on back of machine above reconnect door.
PRIMARY VOLTAGE:
We must have between the ON/OFF LINE SWITCH and the RECONNECT PANEL an alternative voltage :
U1=400V
Leads: T1-T2, T2-T3, T1-T3
SECONDARY VOLTAGE:
The output voltage of the main transformer must be an alternative voltage :
U2=60V
Leads: Phase-Phase ( before the rectifier bridge )
* If the voltage is incorrect, check for loose or broken leads between the reconnect panel and the
ON/OFF POWER SWITCH. Also, test the ON/OFF POWER SWITCH for proper operation.
*
46
Chopper Board Test
you proceed.
DESCRIPTION
This test will help determine if the power module IGBT on the Chopper Board is shorted. This test will
also check for input voltage and if the PWM signal is present to activate the IGBT.
.
MATERIALS NEEDED
Nutdriver
Volt/Ohmmeter
Socket wrench and extension
47
Chopper Board Test
PROCEDURE
1. Disconnect the main AC input power to the machine.

2. Remove the case side panels with a 3/8 in. nutdriver.
3. Locate plug J99. (Later machine do not have J99).
4. Make the following voltage test. From the table below.
5. Turn the machine off between each tests:

a. Carefully insert the meter probes into the back of each Molex plug cavity.
FROM LEAD TO LEAD EXPECTED VOLTAGE

437 ( 1J99) 431 ( 4J99) 20 VDC
If 20 VDC is not present check Digital Power Supply.

For machines that do not have plug J99.
1. Locate B1 and B5 on Chopper Board.
2. Make the following voltage test. See Figure F.3.
3. Check for 80 VDC from B1 to B5.
48
Encoder Test
you proceed.
DESCRIPTION
This test will help determine if the encoders are functioning properly for machines above code 10562.
For earlier codes, we have no test for the encoder board.
.
MATERIALS NEEDED
Volt/Ohmmeter (analog recommended)
Nut driver
PW 345 C Machine Schematic
49
Chopper Board Test
PROCEDURE
1. Disconnect the main AC input power to the machine.

2. Locate the following leads on Plug J85 and J86. See Figure below.
3. Connect main input power to the machine.
4. Make the following voltage tests. From the table below.
5. Turn the machine OFF between each test.
6. Carefully insert the meter probes into the back of each Molex plug pin cavity.
7. As you turn the encoder slowly the voltage will change from zero to15 volts to zero, to 15 volts
etc.as you continue to turn the encoder
FROM LEAD TO LEAD EXPECTED ACTION

VOLTAGE
If you do not read 15VDC on the first reading of encoder #1
855 (5J85) 3243 ( 3J82) 15 VDC 0r #2 then check lead connections. If lead connections check
OK, then Feeder Board may be faulty, replace Feeder Board.
As you turn the encoder #1 or #2 slowly you should see your
8511 ( 11J85) 3243 ( 3J82) 0 OR 15 VDC meter go from 0 to 15, 0 to 15 as you turn the encoder. If not,
check the lead connections. If the lead connection check OK
858 ( 8J85) 3243 ( 3J82) 0 OR 15 VDC then, change the encoder.
WMF/AMPS ENCODER #2
FROM LEAD TO LEAD EXPECTED ACTION

VOLTAGE
If you do not read 15VDC on the first reading of encoder #1
859 (9J85) 3243 ( 3J82) 15 VDC 0r #2 then check lead connections. If lead connections check
OK, then Feeder Board may be faulty, replace Feeder Board.
As you turn the encoder #1 or #2 slowly you should see your
meter go from 0 to 15, 0 to 15 as you turn the encoder. If not,
857 ( 7J85) 3243 ( 3J82) 0 OR 15 VDC
check the lead connections. If the lead connection check OK
then, change the encoder.
50
Wire drive Motor and tachometer feedback test
you proceed.
DESCRIPTION
This test will determine if the wire drive motor and voltage feedback circuits are functioning properly.
.
.
MATERIALS NEEDED
Volt/Ohmmeter
Nut driver
51
Wire drive Motor test
PROCEDURE
NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS.

TEST FOR CORRECT WIRE DRIVE MOTOR ARMATURE VOLTAGE
1. Disconnect main input power to the machine.
2. Open the side panels and remove the tool tray using a 5/16 in. nutdriver.
3. Locate leads 831 and 832 on plug J83.
4. Locate the following leads on plug J83:
5. Connect the main power to the machine.
8. Carefully insert the meter probes into the back of each Molex plug pin cavity to perform the test.
9. Turn the machine ON and use the cold inch button to conduct this voltage test.
MEASURE 1 inch → 25.4 mm
WFS: 2m/min → 3V 78 inch → 3V

5m/min → 7.2V 196 inch → 7.2V
8m/min → 11.32V 314 inch → 11.32V
11m/min → 15.5V 433 inch → 15.5V
14m/min → 19.6V 551 inch → 19.6V
17m/min → 23.7V 669 inch → 23.7V
20m/min → 27.8V 787 inch → 27.8V
21.99m/min → 30.5V 865 inch → 30.5V
PLUG LOCATION: J83
Leads: RED-BLACK ( Feeder Board )
NOTE: Machine without load and without wire
25
20
WFS m/min
15
10
0
3 7 ,2 1 1 ,3 2 1 5 ,5 1 9 ,6 2 3 ,7 2 7 ,8 3 0 ,5
w ire d riv e m o te u r V O L T A G E (d c )
52
Tachometer feedback test
TEST FOR SUPPLY VOLTAGE TO TACHOMETER AND FEEDBACK VOLTAGE
1. Locate the following leads on Plug J84.
3. Turn the machine OFF between each test.

841 ( 1J84 ) 844 ( 4J84 ) 5 Vdc
5. If the 5 VDC is present, go to next step. If no voltage is measured Feeder Head Board may be bad.
Check connections back to Feed Head Board.
6. Locate the leads on Plug J84 noted in the table below.
7. Carefully insert the meter probes into the back of each Molex plug pin cavity
8. Turn the machine ON and pull the gun trigger to conduct the voltage test.
847 ( 7J84) 844 ( 4J84 ) 1.5 to 3.5 VDC
9. If the 1.5 to 3.5 VDC is present, the tachometer circuit is sending the correct feedback signal to the
Feeder Board. Replace the Feeder Board.
10. If the 1.5 to 3.5 VDC is not present or not correct, the Feeder Board is not receiving the proper
feedback voltage from the tachometer circuit. Check the leads from the tachometer circuit to the
Feeder Board for loose or broken connections.
11. If the leads ar okay, the tachometer circuit may be faulty, replace the tach Sensor.
53
Current Transduceur test
you proceed.
DESCRIPTION
This test will determine if the current transducer and associated wiring are functioning correctly..
.
.
MATERIALS NEEDED
Volt/Ohmmeter
Nut driver
54
Current Transducer test
PROCEDURE
TEST PROCEDURE
1. Remove input power to the machine
2. Remove the left case side of the machine.
3. Remove the PC compartment door.
4. Locate plug J8 at the Control Board. Using figure 10.
5. Connect the main power to the machine.
6. Make the following voltage test. From the table below. Also see Table F.1.
802+ (2J8) 806-(6J8) +15 VDC
804- (4J8) 806+(6J8) -15 VDC
8. If excepted voltages are not present the Control Board may be faulty.
9. Check the feedback voltage from the current transducer with the Power Mig set on Mode 1 or 2 and
the machine loaded to 250 amps.
10. Make the following voltage test. From the table below.
801 (1J8) 806 (6J8) 2.0 Vdc
11. If the measured feedback voltage is not correct for the output load current. The current transducer
may be faulty.
12. If for any reason the machine cannot be loaded to 250 amps, Figure 11 shows what feedback
voltage is produced at various current loads.
OUTPUT LOAD CURRENT EXPECTED TRANSDUCER FEEDBACK VOLTAGE
500 4.0
450 3.6
400 3.2
350 2.8
300 2.4
250 2.0
200 1.6
150 1.2
100 0.8
55
DIGITAL POWER SUPPLY BOARD TEST
you proceed.
DESCRIPTION
This test will determine if supply voltage board is functioning correctly..

.
.
MATERIALS NEEDED
Volt/Ohmmeter
Nut driver
56
DIGITAL POWER SUPPLY BOARD TEST
PROCEDURE
PLUG LOCATION/Leads VOLTAGE Vdc

Input voltage: 42 V
J41 Leads: 471-472
J42 Leads: 412-410 +15 V
J42 Leads: 411-410 -15 V
J42 Leads: 408-410 5V
J43 Leads: 431-437 20 V
J43 Leads: 403-401 5v
J43 Leads: 406-405 5V
J43 Leads: 114-113 5V
57
CLEAR ALL PROCEDURE
The Clear All procedure allow to find the set u p weld mode factory. Before to start the
procedure, read and follow the instruction step by step.
1) Machine have not power up.

2)
3) We must turn the two switch button at the same time and keep the position of the
select button push up for the step 2&3.
4)
58
3) Keep the select button push up until the next display code at the next step .
4) Machine must display this code:
5) Turn the right encoder to find the Clear all code.
59
6) Push up the select button one time.
7) Wait a moment.
8) Machine is ready, there is the set up weld mode factory.
60
Lincoln Diagnostic Utility
Introduction
The Lincoln Diagnostic Utility is a software tool used for maintenance and diagnostics of Lincoln
Electric welding equipment utilizing the new digital common controls platform.
This utility is expressly designed for simplicity and straightforwardness. Its simple, yet powerful,
diagnostic features can detect the most subtle problems or misconfigurations.
Getting Started
To begin using the Lincoln Diagnostic Utility, your welding device must be attached to the computer, or
to your local area network (LAN).
When the program starts up, you will need to select which serial port your machine is attached to (the
default port is COM1). When you have selected a port, click the “Connect” button to establish a
connection to the machine. A DB-9 to DB-25 Pin serial adapter cable (swaps pins 2 and 3 from one
end to the other) should be used between the PC and machine (Radio Shack part no. 26-269). Notice
that the “Disconnect” button will become enabled, so that you can disconnect from your machine at
any time.
In addition, advanced users may elect to use the “Connect via Ethernet” button to connect to a
machine that is hooked up to their local area network (LAN).
Once a connection is established, several other “tabs” appear on top of the program’s window.
The “System Info” and “Diagnostics” tabs should appear unconditionally. Once the machine
is in a ready state (no errors), several other functional tabs such as “Calibration” or “Cable
Test” will appear depending on the operating system. In addition, the status bar message at the
bottom of the window will indicate the connection type, and communication protocol of the
machine to which you have connected.
61
1) Diagnostics (ArcLink)
“Diagnostics” is the default window, and displays any problems that might be present in your machine,
no matter how benign the problem might be.
If there are absolutely no problems in your machine, the program will show a green check mark, and
display a “Machine is ready” message, as in the illustration above.
If the program detects a malfunction in your system, it will attempt to ascertain which board caused the
malfunction. For example, in the following figure, the Weld Controller generated an error because it
detected a thermal fault:
62
The “Refresh” button at the bottom will simply re-run the diagnostic process and re-display
the results. If the “Auto” check box is checked, the proram will automatically refresh the
diagnostics every 1 second.
If you click the “Display Status” button, the program will display the status of all logical
objects in your machine, regardless of their condition
In the example above, all objects are ready (no errors) except the Weld Controller object. This
is indicated by a red “x” icon next to the faulted object.
In addition to the actual faulted condition, an object may also have “events” recorded in its
historical Event Log. These events can provide additional information about the cause of any
problem. An event may be residual from a previous malfunction, or it could be associated
with the current malfunction. Even objects that are not faulted may still have events recorded
in their log. Each event has a time stamp and a textual description of the nature of the event.
(The time stamp generally indicates the amount of time elapsed since the machine was
powered up)
63
It is recommended to periodically “clear” the event logs of any object that might have events,
so that, if a problem ever occurs, it will be certain that any logged events will be recent, and
will apply to the problem at hand.
If the machine experiences an error severe enough that the machine is forced to reset, the error
is recorded in the Fatal Error Log.
The Event Logs, Fatal Logs, and Latched Errors (for all objects) can be cleared
simultaneously by clicking the “Clear Logs” button in the bottom right corner of the window
When the logs are cleared in this manner, the machine will remember the last time its logs
were cleared, and this information will be reflected the next time you run the diagnostics:
NOTE: In this test, it’s a direct connection with the PC
64
2) Diagnostics (LincNet)
Earlier code semi-automatic machines utilized the LincNet communication protocol. LincNet
did not support diagnostics as extensive as those available in ArcLink machines. Nor does it
support historical logs, which means once an error has cleared, there is no record of its
occurrence. The LincNet Diagnostics window will only display the latched error(s) that the
machine is presently experiencing, as well as the current status of the machine. For this reason
the “Auto Refresh” option is recommended when troubleshooting a LincNet based machine to
more easily track the error sequences.
Diagram for LincNet diagnostic
65
FAULT/STATUS CODES
// Fault/status codes used byte status LED, UI display and Event Log.
//
// **CANNOT** use 0 as a digit. NO HEX values !!!!!
//
// Boot Fault & Status codes use ranges between 11 and 19
// Power source fault/status codes use ranges between 21 and 79
// Wire drive fault/status codes use ranges between 81 and 89
// Sense Lead fault/status codes use ranges between 91 and 94
// Spool/Pull Gun fault/status codes use ranges between 95 and 99
// Gateway fault/status codes use ranges between 111 and 149
// Ethernet Board Events 161 -
// User Interface events 261 - 289
// Spread Arc / Travel Carriage events 291 - 299
#define ACTION_DB_FAIL 0x0011 // action db failed

- EEF_ACTION_DB_FAIL_struct
#define ATTRERROR 0x0012 // attribute error
- EE_ATTRERROR_struct
#define EE_FAULT_NONVOL_ATTRIB_RESTORE 0x0013 // non-volatile
attributes restore fault -
#define EE_FAULT_PRIMARY_NONVOL_SECTION_BAD 0x0014 // primary non-
volatile section bad -
#define EE_FAULT_SECONDARY_NONVOL_SECTION_BAD 0x0015 // secondary non-
volatile section bad - No Data
#define EE_FAULT_NONVOL_ATTRIB_WRITE_BAD 0x0016 // non-volatile
attributes write bad - EEF_ACTION_DB_FAIL_struct
#define HSL_WDOG_TIMEOUT 0x0017
#define AL_MAP_NOTSIMPLE 0x0018 // not a simple
system - No Data
#define EEF_WS_ENTEREDFAULTSTATE 0x0021 // Fault state

condition - EEF_WS_ENTEREDFAULTSTATE_struct
#define EEF_WS_WCDERROR 0x0022 // Fault state entry
caused by WCD error - EEF_WS_WCDERROR_struct
#define EEF_WS_UPDATEACTIVESTATE 0x0023 // Error updating
active state - EEF_WS_UPDATEACTIVESTATE_struct
#define EEF_WS_MODECHANGE 0x0024 // Error changing
mode data - EEF_WS_MODECHANGE_struct
#define WC_FAULT_PRIM_OL 0x0031 // primary

overcurrent - EEF_WC_STATUS_struct
#define WC_FAULT_CAPA_UV 0x0032 // cap bank 'a'
under voltage - EEF_WC_FAULT_CAP_struct
#define WC_FAULT_CAPB_UV 0x0033 // cap bank 'b'
under voltage - EEF_WC_FAULT_CAP_struct
#define WC_FAULT_CAPA_OV 0x0034 // cap bank 'a' over
voltage - EEF_WC_FAULT_CAP_struct
#define WC_FAULT_CAPB_OV 0x0035 // cap bank 'b' over
voltage - EEF_WC_FAULT_CAP_struct
#define WC_FAULT_THERMAL 0x0036 // thermostat
tripped - EEF_WC_STATUS_struct
#define WC_FAULT_SS_FAILED 0x0037 // Soft start failed
- EEF_WC_STATUS_struct
#define WC_FAULT_MISC_HW 0x0039 // misc hw fault
(thermal or poc) - EEF_WC_STATUS_struct
66
#define WC_STATUS_LONG_AVG_SOL 0x0041 // secondary over
current (long average) - EEF_WC_STATUS_struct
#define WC_FAULT_POWER_DOWN 0x0042 // power down 42
#define WC_FAULT_CAP_DELTA 0x0043 // cap delta voltage
- EEF_WC_FAULT_CAP_struct
#define WC_FAULT_DSP_HB 0x0044 // DSP detects '332
dropped HB - EEF_WC_STATUS_struct
#define WC_FAULT_HI_VOLTS 0x0045 // output voltage
high - EEF_WC_FAULT_HI_VOLTS_struct
#define WC_STATUS_SHORT_AVG_SOL 0x0046 // secondary over
current (short average) - EEF_WC_STATUS_struct
#define WC_FAULT_MISC2_HW 0x0047 // misc hw fault
(cap fault or hb) - EEF_WC_FAULT_CAP_struct
#define WC_FAULT_MISC3_HW 0x0048 // misc hw fault
high (main opened) - EEF_WC_STATUS_struct
#define WC_STATUS_1P 0x0049 // single phase
#define WC_WCSETWS_FAIL 0x0051 // WC Attempt to set
WS schedule memory failed -
#define WC_DSPLOAD_HIGH 0x0052 // DSP load
dangerously high- failure imminent - EEF_WC_DSPLOAD_HIGH_struct
#define WC_SENSE_LOSS 0x0053 // voltage sense
loss - EEF_WC_STATUS_struct
#define WC_FAULT_SEC_OC 0x0054 // secondary
overcurrent
#define WS_SLOPE_TRUNC_TO_ZERO 0x0061 // Slope

calculation truncated to zero
#define WS_FAULT_WCD_RETRY 0x0062 //
Sequencer Weld Cycle Data Retry - EEF_WS_WCDRETRY_struct
#define WD_FAULT_MOTOR_OVERLOAD 0x0081 // motor overload

fault code - EEF_WD_FAULT_struct
#define WD_FAULT_WD_OVERCURRENT 0x0082 // wire drive
overcurrent fault code - EEF_WD_FAULT_struct
#define WD_FAULT_SHUTDOWN_1 0x0083 // shutdown bit 1
- EEF_WD_FAULT_SHUTDOWN_struct
#define WD_FAULT_SHUTDOWN_2 0x0084 // shutdown bit 2
- EEF_WD_FAULT_SHUTDOWN_struct
#define WD_FAIL_FINDING_AC 0x0085 // failed finding
arcobject for trigger command - EE_ATTRERROR_struct
#define WD_FAULT_MOTOR_OVERVOLTS 0x0086 // wire drive input
voltage too high - EEF_WD_FAULT_struct
#define WD_FAULT_UI_NOT_FOUND 0x0087 // wire drive could
not find user interface - GET_AL_OBJ_ADDR_FAIL_struct
#define EEF_SL_POLARITYUPDATE 0x0091 // Failed to update

the polarity attribute - EEF_SL_POLARITYUPDATE_struct
#define SG_FAULT_MOTOR_OVERLOAD 0x0095 // Spool/Pull motor

overload fault code - EEF_WD_FAULT_struct
#define DN_QUEUE_OVERFLOW 0x0111 // StateMem Evt

Queue OverFlowed - No Data
#define DN_ST_TM_EN_ACCESS_FUNC 0x0112 // Err in State
Timer Enable Access Func - No Data
67
#define DN_ST_EN_ACCESS_FUNC 0x0113 // Err in State
Enable Access Func - No Data
#define DN_MODECHANGE_TIMEOUT 0x0114 // Mode change evt
didn't arrive in time - No Data
#define DN_COSEVENT_FAIL 0x0115 // Failed creation
of COS event - DN_EVT_LOG_STRCT_5
#define DN_GETALADDRESS_FAIL 0x0116 // Failed to get the
object's AL address - DN_EVT_LOG_STRCT_5
#define DN_IO_CXN_TIMEOUT 0x0118 // DN IO Cnxn Timed-
Out - DN_EVT_LOG_STRCT_1
#define DN_CXN_DEALLOC 0x0119 // DN Cnxn was
Deallocated - DN_EVT_LOG_STRCT_1
#define DN_WRITE_FAIL 0x0121 // write_db_property
failed - DN_EVT_LOG_STRCT_2
#define DN_READ_FAIL 0x0122 // read_db_property
failed - DN_EVT_LOG_STRCT_2
#define ALWRITE_FAIL 0x0123 // Write failed
setting DN IO Cmds Off - DN_EVT_LOG_STRCT_4
#define MODECHANGE_FAILED 0x0124 // Failed to change
modes - No Data
#define ERR_IN_GET_TRIM_UNSCLD 0x0125 // Err getting
Scaled Trim Value - DN_EVT_LOG_STRCT_3
#define ERR_IN_GET_TRIM_SCLD 0x0126 // Err getting
UnScaled Trim Value - DN_EVT_LOG_STRCT_3
#define ERR_SET_TRIMS_MODE_CHG 0x0127 // Err in setting
trims on a mode change - DN_EVT_LOG_STRCT_3
#define ERR_SETTING_EE_VALS 0x0128 // Err in writting
out an EE value - DN_EVT_LOG_STRCT_2
#define GW_DNATTR_INIT 0x0129 // Err in
initializing dnattrs - DN_EVT_LOG_STRCT_2
#define EE_PARAM_READ 0x0131 // EE Read Failed or
Bad EE Checksum - EE_PARAM_READ_struct
#define EE_PARAM_WRITE 0x0132 // Write to EE
Failed - EE_PARAM_WRITE_struct
#define DN_WRITEALACT_FAIL 0x0133 // Write Arclink
action fail - DN_WRITEALACT_FAIL_struct
#define DN_MSTR_GOT_EXP_FRAG 0x0134 // DN Master got a
Fragmented Exp Msg Response - DN_MSTR_ERROR_STRUCT1
#define DN_MSTR_GOT_BAD_EXP_MSG 0x0135 // DN Master got a
Bad Exp Msg Response - DN_MSTR_ERROR_STRUCT2
#define DN_MSTR_OPEN_SLAVE_FAILED 0x0136 // DN Master could
not open slave - DN_MSTR_ERROR_STRUCT1
#define DN_MSTR_LOST_COMM_TO_SLAVE 0x0137 // DN Master lost
communications to slave - DN_MSTR_ERROR_STRUCT1
#define DN_MSTR_GOT_BAD_IO_MSG 0x0138 // DN Master got a
bad IO Msg Response - DN_MSTR_ERROR_STRUCT3
#define DN_MSTR_BAD_FEEDDRIVE_HI_LIM 0x0139 // DN Master read a
bad hi lim for the Set WFS - No Data
#define DN_MSTR_SEND_POLL_FAILED 0x0141 // DN Master sending
poll IO failed - DN_MSTR_ERROR_STRUCT1
#define DN_ERR_GETTING_MODES 0x0142 // Error in reading
modes from WC
#define DN_SETTING_SPI_DISPLAY_ITEM 0x0143 // Error in setting
SPI panel item - DN_SPI_ERROR_STRUCT
#define DN_GETTING_TRIM_INFO_ACTION 0x0144 // Error in setting
SPI panel item - DN_EVT_LOG_STRCT_4
68
#define ACTION_FAILED 0x0166
//ACTION_FAILED_STRUCT
#define ETHERNET_EUROPIPE_PLC 0x0167
#define ETHERNET_UDP_PORT_BUSY 0x0168 //

- EN_EP_PLC_ERROR_STRUCT
#define ETHERNET_CN_WDOG_TO 0x0169 // When connection
has a watchdog timeout - EN_SOCK_WDOG_ERR_STRUCT
#define ETHERNET_SOCKET_TO 0x0171 // When a socket
times out - EN_SOCK_WDOG_ERR_STRUCT
#define ETHERNET_WDOG_TO 0x0172 // When ethernet
times out - No Data
#define FAILED_TO_CREATE_COS_EVT 0x0173 // Failed creating a
COS event - DN_EVT_LOG_STRCT_5
#define FAILED_TO_GET_AL_OBJ_ADDR 0x0174 // Failed getting an
Arclink OBJ Addr - DN_EVT_LOG_STRCT_5
#define AL_REQUEST_FAILED 0x0175 // An Arclink
message failed - DN_EVT_LOG_STRCT_2
#define INITIALIZING_WEBPAGE_SERVER 0x0176 // Error in setting
up the Web Server - WEB_PAGES_ERR_STRUCT
#define HISPEED_EVT_REG_FAILED 0x0177 // Hi Speed Event
Registration Failed - HI_SPEED_EVENT_STRUCT
#define HS_EVT_READ_FAILED 0x0178 // Hi Speed Event
Read Failed - No Data
#define AL_EVENT_QUEUE_OVERFLOW 0x0179 // A incoming AL
events queue overflowed - No Data
#define FAILED_ADDING_SELF_TO_AL_GRP 0x0181 // Failed to added
self to the Arclink group - No Data
#define ALLOC_TPU_TIMER 0x0182 // Couldn't allocate
TPU timer - FAILED_TO_ALLOCATE_TPU_TIMER_STRUCT
#define DEALLOC_TPU_TIMER 0x0183 // Error in
deallocate TPU timer - FAILED_TO_ALLOCATE_TPU_TIMER_STRUCT
#define OPENNIG_UDP_PORT 0x0184 // Error in openning
UDP Listen Port
#define IP_NOT_IN_CNTRL_RANGE 0x0185 // Non-Authorized IP
sent us an UDP Packet - EN_IP_ERROR_STRUCT
#define BAD_UDP_INPUT 0x0186 // Incoming UDP
Packet bad (# bytes, format,..) - EN_IP_ERROR_STRUCT
#define UDP_ALLOC_FAILED 0x0187 // Could not
allocate a UPD Packet - No Data
#define UPD_SEND_FAILED 0x0188 // Send a UDP packet
failed - No Data
#define UPDATING_CACHE_FAILED 0x0189 // Error in updating
Cache memory - No Data
#define PROBLEM_WITH_UDP_ITEM 0x0191 // Error in checking
UDP cache item - EN_CHECKING_UDP_OUTPUT_ITEM_STRUCT
#define PROBLEM_ADDING_UDP_ITEM 0x0192 // Error in creating
UDP cache item - EN_CREATING_UDP_OUTPUT_ITEM_STRUCT
#define REMOVING_AL_EVENT 0x0193 // Error in removing
an Arclink event - EN_REMOVING_AL_EVENT_STRUCT
#define CLNT_UDP_SEND 0x0194 // Error in send UPD
msg from enet client - EN_CLNT_UDP_SEND_FAILED_STRUCT
#define CLNT_SOCKET_PROBLEM 0x0195 // Had problem with
a client socket call - EN_CLNT_SOCKET_PROBLEM_STRUCT
#define CLNT_OPEN_PROBLEM 0x0196 // Had problem
openning client - EN_CLNT_OPEN_STRUCT
#define CLNT_RECV_DATA_PROBLEM 0x0197 // Client detected
problem with Server data - EN_CLNT_RECV_DATA_STRUCT
69
#define CLNT_TIMED_OUT 0x0198 // Client timeouted
waiting for enet server reply- EN_CLNT_TIMEOUT_STRUCT
#define GETTING_SEQ_XREF 0x0199 // Error get a seq
xref attribute number - XREF_ERR_STRUCT
// the following error codes are used when there is a problem with a specific board
that is needed for machine to operate
#define CONTROL_BOARD_NOT_FOUND 0x212 // control board
can't be found
#define CONTROL_BOARD_OFFLINE 0x213 // control board is
offline
#define WIRE_DRIVE_BOARD_NOT_FOUND 0x214 // wire drive board
can't be found
#define WIRE_DRIVE_BOARD_OFFLINE 0x215 // wire drive board
is offline
#define SENDING_CLNT_MSG 0x0216 // Error sending Msg

to Enet Client - No Data
#define ARC_MASTER_PROBLEM 0x0217 // Arc Master Had a
Problem - EN_ARC_MASTER_PROBLEM_STRUCT
#define ACTION_TO_SEQ 0x0218 // Action to Seq
Failed - SEQ_ACTION_PROBLEM_STRUCT
#define SETTING_SEQ_MEMORY 0x0221 // Had Problem with

updating Seq Mem - SET_SEQ_MEM_STRUCT
#define GET_SEQ_XREF_OVER_ENET 0x0222 // Problem getting
Seq Xrefs - GET_SEQ_ENET_XREF_STRUCT
#define ACCESSING_AO 0x0223 // Problem getting
getting Arc Data - AO_STRUCT
#define ENET_MSG_TO_SERVER 0x0224 // Had problem with
a message to a server - ENET_MSG_STRUCT
#define RESET_BAD_SESSION_ID 0x0225 // Reset, got
different sessionid from server - ENET_SESSION_RESET_STRUCT
#define ENET_MSG_TO_SVER 0x0226 // Had problem with
a message to a server - ENET_MSG_STRUCT2
#define ARC_CNTL_PROBLEM 0x0231 // Arc Cntl Obj

Problem - EN_ARC_CNTL_PROBLEM_STRUCT
#define ARC_CNTL_WRITE_WP 0x0232 // Arc Cntl Obj
WRITE WP - EN_ARC_CNTL_SEQWRITE_STRUCT
#define ARC_CNTL_WRITE_TRIM 0x0233 // Arc Cntl Obj
WRITE TRIM - EN_ARC_CNTL_SEQWRITE_STRUCT
#define ARC_CNTL_WRITE_WAVE1 0x0234 // Arc Cntl Obj
WRITE WAVE1 - EN_ARC_CNTL_SEQWRITE_STRUCT
#define ARC_CNTL_WRITE_WFS 0x0238 // Arc Cntl Obj
WRITE WFS - EN_ARC_CNTL_SEQWRITE_STRUCT
#define ARC_CNTL_WRITE_TIMER 0x0239 // Arc Cntl Obj
WRITE TIMER - EN_ARC_CNTL_SEQWRITE_STRUCT
#define ARC_CNTL_WRITE_STATE_EN 0x0241 // Arc Cntl Obj
WRITE STATE ENABLE - EN_ARC_CNTL_SEQWRITE_STRUCT
70
#define ARC_CNTL_WRITE_TIMER_EN 0x0242 // Arc Cntl Obj
WRITE TIMER ENABLE - EN_ARC_CNTL_SEQWRITE_STRUCT
#define ARC_CNTL_READ 0x0243 // Arc Cntl Obj Read
- EN_ARC_CNTL_READ_STRUCT
#define ARC_CNTL_OBJ 0x0244 // Arc Cntl Obj
Can't Find Object - EN_ARC_CNTL_OBJ_STRUCT
#define ARC_CNTL_WRITE 0x0245 // Arc Cntl Obj non
seq WRITE - EN_ARC_CNTL_WRITE_STRUCT
#define ARC_CNTL_MODE_CHANGE 0x0246 // Arc Cntl Obj mode
change - EN_ARC_CNTL_MODE_CHANGE_STRUCT
#define ARC_CNTL_SYSTEM_FAULT 0x0247 // Arc Cntl Obj
latched fault - ARC_CNTRL_SYSTEM_FAULT_STRUCT
// User Interface event defs

#define UI_DUAL_MEMORY_PANEL_SETTING 0x0261 // Dual Memory Panel
Dip switches not set right -UI_DUAL_HEAD_FAULT_STRUCT
#define POWER_SOURCE_NOT_COMPATIBLE 0x0262 // Power source is
not compatible - POWER_SOURCE_NOT_COMPATIBLE_STRUCT
#define UI_NO_USABLE_WELD_MODES 0x0263 // The UI found no
weld modes it is capable of controlling
#define UI_BAD_WELD_MODE 0x0264 // The UI tried to
select a non-existent weld mode
#define UI_NONSUPPORTED_WELD_MODE 0x0265 // The selected weld
mode is no supported by the UI
#define UI_IO_NOT_READY 0x0266 // The UI I/O is
preventing the UI from becomming ready
#define SA_AT_BOTH_LIMITS 0x0291 // Both limit

switches are simultaneously active
There is also a list of FATAL log errors. The attached file lists some of these errors. Some of the descriptions are
confusing, but hopefully the common errors are described well enough. The list below was taken directly fromn
the software code, but is a pretty good listing.
/***********************************************************************************
***************/
/* #defines FATAL ERROR CODES CANNOT CONTAIN ZEROS FOR
DIGITS!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
They may be HEX values from 1-9, a-f are also PROHIBITED!!!!!!!!!!!!11111
************************************************************************************
***************/
#ifndef fat_defs_h
#define fat_defs_h
/* System exceptions, 100 series. The number blinked on the status led is a hex
number, i.e. each
nibble is blinked like a decimal digit. When expanding this list, be sure not to
include any numbers
already declared in md_syser.h since these too are blinked. A simple rule is to
keep errors
in this file to numbers 111 or larger. */
#define F_UN_INIT 0x111
#define F_BUSERROR 0x112
#define F_ADRERROR 0x113
71
#define F_ILLEGAL 0x114
#define F_ZERODIV 0x115
#define F_CHK 0x116
#define F_TRAPV 0x117
#define F_PRIVILEGE 0x118
#define F_TRACE 0x119
#define F_EMULA 0x121
#define F_EMULF 0x122
#define F_HW 0x123
#define F_PROTO 0x124
#define F_FORMAT 0x125
#define F_UNINIT 0x126
#define F_RESVD 0x127
#define F_SPURIOUS 0x128
#define F_AUTO1 0x129
#define F_TRAP0 0x137
#define F_TRAPA 0x148
#define F_TRAPB 0x149
#define F_TRAPC 0x151
#define F_TRAPD 0x152
#define F_TRAPE 0x153
#define F_TRAPF 0x154
#define F_USER 0x155
#define LAST_EXCEPTION F_USER
/* 0x1111 - 0x11xx are Boot code errors */

#define F_BOOT_CSUM 0x1111
#define F_BOOT_RSR 0x1112 /* Reset Status Register != POW (power on
reset) */
#define F_BOOT_FORCED 0x1113 /* Boot mode forced by jumpering Tx and Rx
lines */
#define F_RAM_FAIL 0x1116 /* Problem with reading RAM correctly */
#define F_DATA_FAIL 0x1117 /* Problem with data or address lines */
#define F_MAP_FAIL 0x1118 /* Problem with mapping */
/* 0x1211 - 0x12xx are OS errors */

#define F_OS_TIMERALLOC 0x1213 /* OS timer could not be allocated */
#define F_EVENT_QSETUP 0x1214 /* bad event queues */
#define F_EVENT_QREAD 0x1215 /* bad event queue read */
/* 0x1311 - 0x13xx are system errors */

#define F_MAIN_CSUM 0x1311 /* Main code checksum error */
72
#define F_PARAM_CSUM 0x1312 /* Parameter file checksum error */
#define F_FPGA_CSUM 0x1313 /* FPGA file checksum error */
#define F_WTABLE_CSUM 0x1314 /* Weld table checksum error */
#define F_DSP_CSUM 0x1315 /* DSP checksum error */
/* F_DSP_CSUM fatal specific codes */
#define FS_DSP_CSUM_MAIN_CODE 0 /* the DSP main conde in FLASH contains an
invalid checksum */
#define FS_DSP_CSUM_BOOTSTRAP_CODE 1 /* the DSP bootstap code in FLASH contains
an invalid checksum */
#define FS_DSP_CSUM_CLEAR_PROG 2 /* the DSP clear program in FLASH contains
#define FS_DSP_CSUM_SET_PROG 3 /* the DSP set program in FLASH contains an
invalid checksum */
#define FS_DSP_CSUM_PROG_PROG 4 /* the DSP program program in FLASH contains
#define FS_DSP_CSUM_SEND_MESSAGE 5 /* the buffer passed to DSP_SendMessage()
contained an invalid checksum */
#define FS_DSP_CSUM_DEPLETION_PROG 6 /* the DSP clear program in FLASH contains
#define F_PARAM_FORMAT 0x1316 /* Parameter file format error */
/* F_PARAM_FORMAT fatal specific codes */
#define FS_PARAM_FORMAT_BAD_HEADER 0 /* the parameter file header format is
invalid */
#define FS_PARAM_FORMAT_BAD_DATA 1 /* the parameter file data format is invalid
*/
#define F_HW_REV_FORMAT 0x1317 /* Hardware Revision format error */

#define F_CANNOT_AUTOMAP 0x1318 /* System configuration is incompatible with
automap feature */
/* 0x2111 - 0x2xxx are LINC-NET/CAN errors */

#define F_CAN_SPUR 0x2111 /* can spurious interrupt, status has not
intr source set */
#define F_CAN_OBJSPUR 0x2112 /* can spurious interrupt, source object
status <> pend */
#define F_CAN_ERRSPUR 0x2113 /* can spurious interrupt, error status intr
not enabled */
#define F_CAN_OBJALLOC 0x2114 /* can object allocation error */
#define F_CAN_WCYC_SEQ 0x2115 /* can weld cycle blocks out of sequence */
#define F_CAN_BWRN 0x2116 /* can bus warn */
#define F_CAN_BOFF 0x2117 /* can bus error */
#define F_CAN_NOTNEW 0x2118 /* can object 15 was data (following
interrupt) not new */
#define F_CAN_NORESET 0x2119 /* CAN hardware did not come out of reset */
/* 0x3111 - 0x3xxx are HSL errors */

#define F_HSL_SPURTX 0x3111 /* HSL spurious tx interrupt */
#define F_SER_BADMAIL 0x3112 /* Mail for serial download request was bad
*/
/* 0x4111 - 0x4xxx are Flash program errors or EEPROM errors*/

#define F_FPRG_SUPPORT 0x4111 /* Flash programming not supported in main
code */
#define F_EE_SECT_NUM_INVALID 0x4211 /* specified EEPROM section number is
invalid */
#define F_EE_2_MANY_NV_ATTRIBS 0x4212 /* too many nonvolatile attributes found */
#define F_EE_NV_ATTRIB_CHECKSUM 0x4213 /* non-volatile attribute EEPROM checksum
invalid after save all */
73
#define F_EE_SECT_OVRLAP 0x4214 /* EEPROM defined sections overlap */
#define F_EE_SECT_SIZE 0x4215 /* EEPROM defined section smaller than
section header size */
#define F_EE_SECT_LOG_OVRLAP 0x4216 /* Log section of EEPROM is calculated
larger than allocated */
/* 0x5111 - 0x5xxx are misc errors*/

#define F_FGEN_BUSY 0x5111
#define F_DNATTR_INIT 0x5112 /* Unable to init DN attribute */
/* 0x6111 - 0x61xx are sequencer errors */

#define F_SEQ_BADWCYC 0x6111
#define F_SEQ_WRITE_ERR 0x6112
#define F_SEQ_BUILD_ERR 0x6113
#define F_SEQ_BUILD_CFG 0x6114
#define F_SEQ_BUILD_CON 0x6115
#define F_SEQ_MEM_OVERFLOW 0x6116
/* 0x6211 - 0x62xx are weld controller errors */

#define F_WC_WTABLE_EMPTY 0x6211
#define F_WC_WTABLE_BAD 0x6212 /* Some error other than an empty weld table
*/
/* 0x6311 - 0x63xx are wire drive errors */

#define F_WD_NOISY_WFS_INPUT 0x6311 /* If get NUM_SHORT_TACH_PERIODS in a row,
WFS tach input was noisy and can't be used */
/* 0x6411 - 0x64xx are Ethernet errors */

#define F_EN_PG_GOT_MAPPED 0x6411 /* Stand alone Phase Generator got mapped */
/* 0x7111 - 0x71xx are SPI errors */

#define F_SPI_UNKNOWN_PANEL 0x7111 /* an SPI panel was detected that could not
be found in the panel database */
#define F_SPI_PANEL_RAM 0x7112 /* not enough panel RAM has been pre-
allocated to support a given SPI panel */
#define F_SPI_PANEL_0_BAD_DATA 0x7121 /* repeated bad data read from panel 0 (only
fatal if panel is essential) */
#define F_SPI_PANEL_0_ESSENTIAL 0x7131 /* panel 0 is considered "essential" to
operation and is not installed */
74
/* 0x8111 - 0x81xx are DSP errors */

#define F_DSP_FPGA_LOAD_FAILURE 0x8111 /* an error occurred while transfering DSP
code from main FLASH to FPGA registers */
#define F_DSP_CLEAR_FAILURE 0x8112 /* the DSP clear program could not clear
(=0) all DSP FLASH bits */
#define F_DSP_SET_FAILURE 0x8113 /* the DSP set program could not set (=1)
all the DSP FLASH bits */
#define F_DSP_PROGRAM_FAILURE 0x8114 /* the DSP program program could not program
the DSP FLASH properly */
#define F_DSP_VERSION_CHANGED 0x8115 /* the DSP version number changed since an
initial read at powerup */
#define F_DSP_RAM_ERROR 0x8116 /* the DSP reported a ram error status at
sys_init */
#define F_DSP_CSUM_ERROR 0x8117 /* the DSP reported a checksum error status
at sys_init */
#define F_DSP_HB_ERROR 0x8118 /* the DSP reported a heartbeat error */
#define F_DSP_PROGRAM_TIMEOUT 0x8119 /* the DSP did not respond within the
required amount of time while programming */
#define F_DSP_WATCHDOG_TIMEOUT 0x8121 /* the DSP is no longer operating */
#define F_DSP_DEPLETION_FAILURE 0x8122 /* the DSP depletion program could set (=1)
all the DSP FLASH bits using delpletion algorithm */
#define F_FPGA_BAD_CFG 0x9111 /* FPGA has a bad configuration (CRC) */

#define F_FPGA_NO_PRG 0x9112 /* FPGA programming fault */
#define F_TCP_STACK 0x9511 /* Ethernet Stack report a problem */
75
Retest after Repair
76
ELECTRICAL DIAGRAM
WIRING DIAGRAM
77
ANNEXE
FEEDER BOARD
PLUG LOCATION
78
79
SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions
as to additional tests or procedures that would make this SVM a better tool for you. If
you discover new or different “Problems or Symptoms” that are not covered in the
three column troubleshooting chart, please share this information with us. Please
include the machine’s code number and how the problem was resolved.
Thank You,
Service Department
Lincoln Electric France

Avenue Franklin ROOSEVELT
BP 232
76 121 Le Grand Quevilly Cedex
France
FAX +33(0)2 32 11 40 52
EMAIL : LEFservice.dept@LincolnEurope.com
SVM Number ___________________________

Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
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80

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Page Accueil

Safety Depends on You

Lincoln arc welding and cutting

LINCOLN ELECTRIC FRANCE

POWER WAVE 345C s/n

conforms to the following directives:

EN 50199, EN 60974-1, EN 60974-5

CE COMPLIANCE: This equipment complies to the European Communities directives.

TECHNICAL SPECIFICATIONS – PW 345 C

• Do not touch electrically live parts such as output terminals or

Only qualified personnel should install, use, or service this equipment.

Location and Ventilation

Input Supply Connection

300A @ 60% 70 mm²

Connecting the Welding Gun

When this switch is held in the up position, the gas

Control/Display Front Panel.

This panel provides a selection of over 30 weld modes,

To adjust a set up parameter (Weld Mode being

K10353-2 Remote control box

K10362-1 2-idle roll kit for KP10344, 2-roll drive configuration

ELECTRIC SHOCK can kill.

ROUTINE AND PERIODIC MAINTENANCE

MAJOR COMPONENT LOCATIONS

item Part number Description Qty

item Part number Description Qty

GENERAL EXPLODED VIEW

item Part number Description Qty

Input Line Voltage and Main Transformer

Input Rectifier, Chopper Assembly and Feedback

Diode Control Rectifier and Power Board

Weld Control Board

Wire drive motor and feedback

Over Current Protection

Wire Feeder Overload Protection

INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION

Pulse width Modulation

Chopper Technology Fundamentals

How to use troubleshooting guide

PC Board Troubleshooting Procedures

ELECTRIC SHOCK can kill.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

Major physical or electrical damage 1. Contact your local authorized

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

CHOPPER BOARD CAPACITOR DISCHARGE PROCEDURE

CHOPPER BOARD CAPACITOR DISCHARGE PROCEDURE

ELECTRIC SHOCK can kill.

Refer to Figure F.1.

Main Transformer voltage Test

The ON/OFF POWER SWITCH will be "hot" during these tests.

Chopper Board Test

1. Disconnect the main AC input power to the machine.

5. Turn the machine off between each tests:

FROM LEAD TO LEAD EXPECTED VOLTAGE

If 20 VDC is not present check Digital Power Supply.

1. Disconnect the main AC input power to the machine.

FROM LEAD TO LEAD EXPECTED ACTION

FROM LEAD TO LEAD EXPECTED ACTION

Wire drive Motor and tachometer feedback test