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Lincoln Electric IM736-D User's Manual

1. 2825485 26601 3405 303 00 SIN HIMOd WVYOVIC 9NISIM 2 LINCOLN Jequunu epoo eu SAIN 104 221m9 s eui sjeued einsoj oue y euo uo y LL episui pejsed s epoo sejnomed 104 oyioeds siy Aq 104 eq jou 104 S SIUL 310 1323 059 318V2 5723 Way 106 40 391 39N3n03S ALIAVI 319V 143238 TANVd 9 08 30 301S LN3NOdNOO NOW GAVANA 5 HOLIINNOD nu HE HE 5 00006000 03909 330333 8 10095 145 sod MC MOTEANT 330 5 m 3IIHM M HO HO YOVT8 8 300990100 n
2. mOo lt ra POWER MIG 300 Il 1 1 N 2 WIRING DIAGRAMS 11130 NOILOANNOO 2 avo TEH S 9 5 24 4 We 1 ome 9 lt lt lt lt E V 277 5 5 a aeS a Q amp vO8 AlddNS YIMOd TV LI aasia 2960 3009 00 DIN YIMOd WVelovia ONIMIM F 1 LINCOLN E Jequunu epoo eu SAIN 104 221m9 s eui sjeued einsoj oue y euo uo eui CN u episui pejsed si epoo sejnomed 104 oyioeds siy Aq eq jou Ajuo 104 1 SIUL LON 3 Nid 6 1 40 301S WOU 39491038 ALAVO TANVA WOH4 SH NHCHS asvo TV HO
3. 25596 319 NN09 OnlS DOHI NMOHS n o 18 9 avay TIS 1W130 NOLLO3NNOO GHVOY 2 4 aawo Lad ame O EEIE FF FT J Qqavoa AlddNS WL 86011 L601 53002 00 SIN YAMOd WVYOVIC SNISIM F 4 POWER MIG 300 LINCOLN E TEC6TW T N POWER MIG 300 LINCOLN 5 NOTES POWER MIG 300 LINCOLN NOTES POWER MIG 300 LINCOLN P WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Si
4. o 0 SAAD FAIS HHR ele BEHE ET Saal gl illai aul Gud al ply Gail guet ag ls LINCOLN 5 e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
5. Erkennen B 2 B 8 Setting and Configuring the POWER MIG 300 for welding e B 4 Multi Process Panel Functions B 5 B 6 V TCIPITio ess B 7 Procedure for Changing Drive and Idle Roll Sets B 8 Wire R el Ber e dome eine B 8 Mounting of 10 10 44 168 Spools sinnis aE B 8 Feeding Wire Electrode B 9 Idle Pressure Settings rte 9 Avoiding Wire Feeding Problems B 9 Special Welding Processes Available senes B 10 Pulse On Pulse and Benefits of Pulse On Pulse B 11 Power Mode nine Ania en Hr dant ee ines B 12 LoPCCCQII Section C Drive SERRE C 1 Aluminum Feeding 2 etant re ien red C 1 Readi Reel Adapter dndeety C 1 Dual Cylinder 1 Alternative Magnum GMAW Gun and Cable 0 C 1 Magnum Gun Connection ie eet nette C 1 Spool Gun Prince M XL detnr erede ents eases derit fien lore le Feiern C 1 Push Pull Feeding Connection Adapter Kit C 2 Making Weld with the Prince XL or Cobra Gold Torch Installed C 2
6. Mar 93 for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please co
7. Observe Safety Guideline detailed in the beginning of this manual PROBLEMS SYMPTOMS Output voltage and wire feed is pre sent when gun trigger is not pulled not activated Machine output is low Welds are cold weld bead is rounded or bumped up demonstrating poor wet ting into plate Poor arc striking with electrode sticking or blasting off POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check Weld Mode to make sure the unit is ina CV Mode And not a Mode Remove gun assembly from machine If problem is solved gun assembly is faulty Repair or replace If problem persists when gun assembly is removed from machine then the problem is within the POWER MIG 300 Check input voltage Make sure input voltage matches name plate rating and reconnect panel configuration Make sure settings for wire feed speed and voltage are correct for process being used Make sure output polarity is cor rect for process being used Check welding cables and gun assembly for loose or faulty con nections Make sure settings for wire feed speed and voltage are correct for process being used The Run In Fastor Slow speed may be wrong for process and technique being used See Operation Section The gas shielding may be improper for process being used RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem p
8. lt ATATAMA 30 30S LN3NOdNODNO HA JL SON3ND3S ONIHIBNNN ALAYI HOLOSNNOO H gt 4 rs 5 ooooooo loooooooo T B 7 84815 N330 0 oo 9 658 oise 298 4 svo i 1 Es EZ JON3HdAV INYO 10095 WRUSLION fuent wou SHAIOON3 TANVd 1 Oona 460 Would 87 NBI gy 100 mOo lt ra POWER MIG 300 I dSIN 2 WIRING DIAGRAMS Nez wos 09193102 QOnlS OHI NNOHS n QvO8 4 IV130 NOLLO3NNOO 8 D d EL ess n TT 91934 rmm qm 177 z quvog aog Quvog 5 5 Q amp vO8 AlddNS TL masw
9. Hecommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders
10. S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria 9 fsUPBHEILTASESUCFEU e Fat ie es zzv 24758 else SUAS MAS sis PARAH 7 Turn power off before servicing Desconectar el cable de ali mentaci n de poder la maquina antes de iniciar cualquier servicio e D
11. branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas AVFFVA F EAZLRUP PSB ET BRAY FE e HMDS RK AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas OSILDI RALE CHRRIARRARS SHAE Ro e 20 Sel AE Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O it ie BIR Chinese Qai ge dul ale f bi e os Qui BALL cal sd ue pha J gail e cuts il gall l y e Ll gt LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA CL TRHORERMEI HS 85 ET REL BE SUCR Rr de OE D
12. LINCOLN E Jequunu epoo y qjueueoe dai e 4 eu au sjeued eunsojoue y jo euo uo eu LL opisui paysed si opoo 104 enueui siy Aq 104 jou Ajuo SI SIUL 310 101439384 20 VAT NOM 3031038 ONREEWNN ALIAVO 3TOVLdORY ILI Y30334 ENHANCED DIAGRAM lt over 70088 185 oise 198 1 1 TINd HSNd INNO 10095 Ize SAAVISIM WISLISLCTOA DO TIN HSNd QWO8 T4 EZ 9 wl a NNO 10045 Sms Y 90 D dSW mOo lt ra 2 WIRING DIAGRAM d c
13. Maite ane c n Section D Safety Precautions General Maintenance D 1 Drive Rolls and Guide D 1 Contact Tip and Gas Nozzle Installation D 1 Gun Tubes and Nozzles Gun Cable Cleaning D 1 Liner Removal and Replacement nennen nnnm nnne D 2 Troubleshooting contrata ra do rct initi td uii Section E How to Use Troubleshooting Guide E 1 Troubleshooting E 2 thru E 5 Rer CER E 6 Push Pull Gun Wire Feeder Troubleshooting ess E 7 thru E 10 B JE 1e LE U Section F Wiring Diagrams and Dimension Print F 1thru F 5 Parts Appendix POWER MIG 300 Parts Pages siiis nanus s enpara ania P409 Series Magnum 300 amp 400 GMAW Gun Connector Assembly P202 C Series vi A1 INSTALLATION Ani TECHNICAL SPECIFICATIONS POWER MIG 300 INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 230Amp Rated Output Input Current 300 Amp Rated Output 208 230 460 575 60 Hz 48 43 22 17 Amps 72 62 31 25 Amps RATED OUTPUT Input Voltage Amps Volts at Rated Amperes 208 300 Amps 32 Volts 230 460 575 300 Amps 32 Volts 208 230 460 575 230Amps 29 Volts OUTPUT Welding Current Range Continuous
14. arc between pulses See Figure B 5 OPERATION B 10 Pulsed MIG is an advanced form of welding that takes the best of all the other forms of transfer while minimiz ing or eliminating their disadvantages Unlike short cir cuit pulsed MIG does not create spatter or run the risk of cold lapping The welding positions in pulsed MIG are not limited as they are with globular or spray and its wire use is definitely more efficient Unlike the spray arc process pulsing offers controlled heat input that allows better welding on thin materials lower wire feed speeds and leads to less distortion and improved overall quality and appearance This is especially important with stain less nickel and other alloys that are sensitive to heat input In GMAW P mode arc control adjusts the background current and frequency of the wave When arc control goes up the frequency increases thus increasing the droplet transfer rate FIGURE B 5 EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL B lt x lt Lu oO lt lt FREQUENCY gt SPRAY TRANSITION CURRENT POWER MIG 300 LINCOLN B 11 PULSE ON PULSE GMAW PP Pulse on Pulse is a Lincoln process specifically designed for use in welding relatively thin less than 1 4 thick aluminum See Table 3 It gives weld beads with very consistent uniform ripple In Pulse on Pulse modes two distinct pulse types are used instead of the single pulse type
15. at the POWER MIG 300 does not control the WFS at the spool gun Rather it is adjusting the POWER MIG 300 synergic work point Therefore adjusting the SPD value will not change your actual WFS at the spool gun WFS can only be changed at the spool gun PUSH PULL FEEDING CONNECTION ADAPTER KIT K2154 1 The push pull adapter kit provides direct connection of a Cobra Gold or Prince XL torch to the POWER MIG 300 wire feeder welder The kit is intended for use with the following Cobra Gold or Prince XL torches ir Cooled 15 5bm 1589 1 Water Cooled 15 5m K1590 1 ir Cooled 25 8m 1589 2 Water Cooled 25 8m K1590 2 ir Cooled 50 15m 1589 3 Water Cooled 50 15m K1590 3 ir Cooled 15 5 1591 1 Water Cooled 15 5m K1592 1 ir Cooled 25 8 K1591 2 Water Cooled 258m K1592 2 ir Cooled 50 15m K1591 3 Water Cooled 50 15m K1592 3 CAUTION Remove all input power to the POWER MIG 300 before installing the Connection Adapter Kit WARNING Refer to the Owner s Manual of the Torch for Amperage and Duty Cycle rating information The torch rating may not match the rating of the power source MAKING A WELD WITH THE PRINCE XL OR COBRA GOLD TORCH INSTALLED Set the idle roll pressure on the wire drive between an indicator reading of 0 2 A recommended start pointis 1 5 e Set the Gun Selection toggle switch located inside the wire drive compartment directly above the push pull control
16. ble lectrode autour de n importe quelle partie PRECAUTIONS DE SURETE POUR Un coup d arc peut tre plus qu un coup de soliel LES MACHINES A SOUDER A nd TRANSFORMATEUR ET soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs d
17. described later in this Manual When using a spool gun however although the synergic pulsed modes are still accessible they must be used in a non synergic manner as described in the Accessory Section The digital microcomputer based control system allows easy and accurate adjustment of weld parame ters through the multi process panel located on the front of the machine The POWER MIG 300 is equipped with a 6 pin and 7 pin connector to allow operation of a push pull gun for feeding aluminum wires a spool gun remotes and a foot amptrol B 2 Other features Optional kits are available for push pull welding spool gun operation push feeding of 3 64 aluminum with the standard POWER MIG 300 gun and wire feeder A Dual Cylinder Mounting Kit is also offered CONTROLS AND SETTINGS See Figure B 1 1 WIRE FEED SPEED WFS AMP METER This meter displays either the WFS or current value Amps depending on the status of the machine Located below the display is the text WFS and Amps An LED light is illuminated to the left of one of these units to indicate the units of the value dis played on the meter Prior to CV operation the meter displays the desired preset WFS value Prior to CC Stick and CC GTAW operation the meter displays the preset current value During Welding the meter displays actual average amps After welding the meter holds the actual current value for 5 seconds During this time the display i
18. fumes e Use ventilation or exhaust to remove fumes from breathing zone and general area WELDING SPARKS can cause fire or explosion Keep flammable material away v td 5 Be Do not weld on closed contain ers ARC RAYS can burn eyes and skin e Wear eye ear and body protec tion NM Observe all safety information through out this manual ONLY QUALIFIED PERSONNEL SHOULD INSTALL USE OR SERVICE THIS EQUIP MENT UNCRATING THE POWER MIG 300 Cut banding and lift off cardboard carton Cut banding holding the machine to the skid Remove foam and corrugated packing material Untape accessories from Gas Bottle Platform Unscrew the two wood screws at the Gas Bottle Platform holding the machine to the skid Roll the machine off the skid assembly LOCATION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air pas sages and cause overheating INPUT POWER GROUNDING AND CONNECTION DIAGRAMS 1 Before starting the installation check with the local power company if there is any question about whether your power supply is adequate for the volt age amperes phase and frequency specified on the welder nameplate Also be sure the planned installation will meet the U S National Elect
19. gas nozzle and from tip after each 10 minutes of arc time or as required GUN CABLE CLEANING To help prevent feeding problems clean cable liner after using approximately 300 pounds 136 kg of electrode Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using an air hose and only partial pres sure gently blow out the cable liner from the gas dif fuser end POWER MIG 300 Me D 2 MAINTENANCE i CAUTION Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out If this has been done and feed prob lems are experienced try liner replacement and refer to trouble shooting section on rough wire feeding LINER REMOVAL AND REPLACEMENT SEE FIGURE D 1 LINER REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM 300 NOTE The variation in cable lengths prevents the interchangeability of liners between guns Once a liner has been cut for a particular gun it should not be installed in another gun unless it can meet the liner cutoff length requirement Liners are shipped with the jacket of the liner extended the proper amount 1 Remove the gas nozzle 2 Remove the gas diffuser from the gun tube If gas diffuser contains a small set screw loosen the set screw Lay gun and cable out straight on flat surface Loos
20. hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side iw Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable
21. in the rear wire drive torch Make sure the torch drive rolls are tightened slightly to help the wire jump the gap Slow down wire feed speed while pushing wire through torch liner Recommend setting 350 ipm If problem continues after a thru If all recommended possible areas c are checked then the Stall of misadjustment have been Factor Number needs to be checked and the problem persists decreased See Stall Factor Contact your local Lincoln Number Adjustment Authorized Field Service Facility Arc length varies while welding arc PM 300 drive rolls set too tight length is not constant The tension arm should be set at 1 to 1 1 2 Check to see that the spindle brake is not set too tight There should be an aluminum spacer behind the spindle brake Refer to the push pull connection kit for this spacer Clean or replace contact tip problem continues after a and c are checked then the Stall Factor Number needs to be increased See Stall Factor Number Adjustment CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER MIG 300 LINCOLN 5 E 9 TROUBLESHOOTING E 9 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT
22. is changing HHF on steady Machine output 5 on Left display is current right display is voltage If actively welding the displays are arc current and arc voltage If not actively welding the display will show work point CH HHHP blinking Weld just finished the average arc voltage and current will be blinked for 5 seconds following a weld If the work point changes during this 5 second period the display will revert to the above mode CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER MIG 300 LINCOLN 5 E 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION PUSH PULL WIRE FEEDING PROBLEMS While loading wire the rear drive 1 Check torch cable for kinks rolls stop while pushing wire Torch cable should be laid out through the torch relatively straight Check to see that the spindle brake is not set too tight There should be an aluminum spacer behind the spindle brake Refer to the push pull connection kit for this spacer Check the wire at the spool Make sure wire is not crossed If all recommended possible areas and is de reeling properly of misadjustment have been che
23. making certain the spindle brake pin enters one of the holes in the back side of the spool Note an arrow mark on the spindle lines up with the brake holding pin to assist in lining up a hole Be certain the wire comes off the reel in a direction so as to de reel from the top of the coil POWER MIG 300 LINCOLN 5 B 9 OPERATION B 9 4 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining ring groove on the spin dle FEEDING WIRE ELECTRODE WARNING When triggered the electrode and drive mecha nism are electrically hot relative to work and ground and remain hot several seconds after the gun trigger is released NOTE Check that drive rolls guide plates and gun parts are proper for the wire size and type being used Refer to Table C 1 in ACCESSORIES section 1 Turn the Readi Reel or spool until the free end of the electrode is accessible 2 While securely holding the electrode cut off the bent end and straighten the first six inches If the electrode is not properly straightened it may not feed properly through the wire drive system 3 Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine Lift the cast idle roll assembly and allow it to sit in an upright position Leave the outer wire guide plate installed Manually feed the wire through the incoming guide bushin
24. normally used in GMAW P A number of high energy pulses are used to obtain spray transfer and transfer metal across the arc Such pulses are shown in Figure B 6 After a number N of such pulses depending on the wire feed speed used an identical number N of low ener gy pulses are performed These low energy pulses shown in Figure B 6 do not transfer any filler metal across the arc and help to cool the arc and keep the heat input low FIGURE B 6 N PULSES N PULSES LOW HEAT PULSES PEAK BACKGROUND AMPS TIME HIGH HEAT PULSES The Peak Current Background Current and Frequency are identical for the high energy and low energy pulses In addition to cooling the weld down the major effect of the low energy pulses is that they form a weld ripple Since they occur at very regular time intervals the weld bead obtained is very uniform with a very consistent ripple pattern In fact the bead has its best appearance if no oscillation of the welding gun whipping is used See Figure B 7 FIGURE B 7 OPERATION B 11 When Arc Control is used in the Pulse on Pulse modes it does the same things it does in the other pulsed modes decreasing the Arc Control decreases the droplet transfer and weld deposition rate Increasing the Arc Control increases the droplet trans fer and weld deposition rate Since Arc Control varies weld droplet transfer rate the Arc Control can be used to va
25. parameter The setting is shown on the display meter 6 ON OFF POWER SWITCH POWER MIG 300 LINCOLN P B 4 OPERATION ii SETTING AND CONFIGURING THE POWER MIG 300 FOR WELDING e Check that the electrode polarity is correct for the process and turn the Power Switch to the ON position After the boot up period approximately 20 seconds the POWER MIG 300 will default to the last preset weld mode that was active when the machine was powered down The Multi Process Panel defaults with the Weld Mode active e Toggle the SET switch to the desired Weld Mode opera tion The Multi Process Meter displays a weld mode num ber corresponding to a CC or CV welding process as detailed by the chart on the right side of the panel In the example shown in Figure B 2 3 is displayed above the SET switch This means that the machine is set for CC GTAW TIG welding Toggle the SELECT switch to activate the weld parame ters for the selected weld mode Set each parameter using the SET switch to adjust the parameter displayed on the display meter NOTE If the LED next to the weld parameter is flashing the WFS AMP and or the Volt Trim values can also be adjusted for that parameter using the control knobs below each dis play meter An LED below each of the displays will also be flashing to indicate which value is adjustable The Table B 1 shows which weld parameters are adjustable for a given weld mode The weld paramete
26. resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 2 FUMES AND GASES can be dangerous 40 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in con
27. should be located Away from areas where they may be struck or subjected to physical damage e A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment CGA publication 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations SAFETY PRECAUTIONS DE SURETE 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions s ret specifiques qui parraissent dans man
28. that the fuses or breaker keeps tripping breakers are properly sized See installation section of the manual for recommended fuse and breaker sizes Welding procedure is drawing too much output current or duty cycle is too high Reduce output current duty cycle or both There is internal damage to the power source Contact an autho rized Lincoln Electric Service facility Machine will not power up No lights 1 Make certain that the power switch is in the ON position Input voltage selection made all recommended possible areas improperly Power down check of misadjustment have been input voltage reconnect accord checked and the problem persists ing to diagram on reconnect Contact your local Lincoln cover Authorized Field Service Facility Machine won t weld can t get any 1 If the displays show an Err see the fault section for correc tive action If the displays are not lit refer to machine will not power up sec tion If the thermal symbol is lit refer to the thermal section Thermal symbol is lit Check for proper fan operation Check for material blocking intake or exhaust louvers CAUTION for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER MIG 300 LINCOLN amp E 3 TROUBLESHOOTING E 3
29. the above steps AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures a Do not kink or pull cable around sharp corners b Keep the gun cable as straight as possible when welding or loading electrode through cable c Do not allow dolly wheels or trucks to run over cables d Keep cable clean by following maintenance instruc tions e Use only clean rust free electrode Lincoln elec trodes have proper surface lubrication f Replace the contact tip when the arc starts to become unstable or the contact tip end is fused or deformed g Keep wire reel spindle brake tension to the mini mum required to prevent excess reel over travel which may cause wire loop offs from the coil h Use proper drive rolls and wire drive idle roll pres sure for wire size and type being used POWER MIG 300 LINCOLN 5 B 10 SPECIAL WELDING PROCESSES AVAILABLE ON THE POWER MIG 300 PULSE WELDING GMAW P The pulsed arc process is by definition a spray trans fer process wherein spray transfer occurs in pulses at regularly spaced intervals In the time between pulses the welding current is reduced and no metal transfer occurs Pulsed arc transfer is obtained by operating a power source between low and high current levels The high current level or pulse forces an electrode drop to the workpiece The low current level or background maintains the
30. the wire sizes they will feed If a wire size other than that stamped on the roll is used the drive roll must be changed For instructions on replacing or changing drive roll see Wire Drive Rolls in Operation section CONTACT TIP AND GAS NOZZLE INSTALLATION a Choose the correct size contact tip for the elec trode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser b Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser NOTE Insulator is not required when using the optional fixed gas nozzles c Slip the appropriate gas nozzle onto the nozzle insulator Adjustable gas nozzles are available with 62 15 9 mm or 50 12 7 mm I D and in both standard flush and recessed design The proper nozzle should be selected based on the welding application Different length fixed nozzles are also available to fit 300 and 400 amp gun tubes to allow either spray or short circuiting transfer welding Choose the gas nozzle as appropriate for the GMAW process to be used Typically the contact tip end should be flush to 12 3 1 mm extended for the short circuiting transfer process and 12 3 1 mm recessed for spray transfer For the Outershield FCAW process 1 8 3 mm recess is recommended GUN TUBES AND NOZZLES a Replace worn contact tips as required b Remove spatter from inside of
31. welding cables and welding machines 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety nes minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 1 f Do not put your
32. 1 4 700 9 1 700 8 5 Not Not Herman WFS WFS POWER MIG 300 LINCOLN 5 C 1 ACCESSORIES C1 English Wire Metric Wire Length Part No Size Size DRIVE ROLL KITS Refer to Table C 1 for various drive roll kits that are available for the POWER MIG All items in Bold are supplied standard with the POWER MIG TABLE C 1 023 030 0 6 0 8 mm 1696 0305 035 0 9 mm KP1696 035S 045 1 2 mm KP1696 045S KP 1696 2 KP 1696 1 1697 045C KP 1695 3 64A 040 1 0mm 035 045 0 9 0 2mm 035 0 9 mm 045 1 2 mm 3 64 1 2 mm 035 Aluminum recommended for P ush P ull systems only 3 64 1 2 mm ALUMINUM FEEDING KIT K2153 1 This kit helps push feeding aluminum through stan dard machine feeder and gun It provides gun and wire drive conversion parts to weld with 3 64 1 2 mm aluminum wire 5356 alloy aluminum wire is rec ommended for best push feeding performance Kit includes drive rolls and wire guide plate for the wire drive liner and two contact tips for the gun along with installation instructions K363P READI REEL ADAPTER The K363P Readi Reel Adapter mounts to the 2 spindle It is needed to mount the 22 30 Ib Readi Reels DUAL CYLINDER MOUNTING KIT K1702 1 Permits stable side by side mounting of two full size 9 dia x 5 high gas cylinders with no lift loading Simple installation and easy instructions prov
33. Maximum Open Circuit Voltage Welding Voltage Range 5 350 Amps 67 Volts 10 45 Volts RECOMMENDED INPUT WIRE AND FUSE SIZES SINGLE PHASE Input Voltage 230Amps 300Amps 75 C Copper Wire Frequency Hz 29 Volts 32 Volts AWG IEC or 100 Duty Cycle 60 Duty Cycle Sizes Breaker Size 208 60 6 16 mm 230 60 6 460 60 10 575 60 12 2 5 mm NOTE Use 10 AWG Grounding Wire For 208V Input ONLY The duty Cycle Rating at 300 Amps is 40 PHYSICAL DIMENSIONS Height Width Depth Weight 31 79 in 18 88 in 38 78 in 255 lbs 808 mm 480 mm 985 mm 116 kg WIRE SPEED RANGE Wire Speed 50 700 IPM 1 27 17 8 m minute POWER MIG 300 LINCOLN sie INSTALLATION iin Read entire installation section before starting installation SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e Always wear dry insulating gloves Do not use AC welder if your clothing cloves or work area is damp or if working on under or inside work piece Use the following equipment Semiautomatic DC constant volt age wire welder DC manual stick welder AC welder with reduced voltage control Do not operate with panels removed Disconnect input power before servicing J FUMES AND GASES be dangerous Keep your head out of
34. RETURN TO MAIN MENU IM736 D POWER MIG 300 en For use with machine Code Numbers 10562 10952 10958 11000 11097 11098 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 thought ful 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 MT OPERATOR S MANUAL ISO 9001 Fr 7 Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LINCOLN Copyright 2004 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer
35. S COURSE OF ACTION PUSH PULL WIRE FEEDING PROBLEMS During Welding the wire continues 1 Check to see that the spindle to burn back to the tip brake is not set too tight There should be an aluminum spacer behind the spindle brake Refer to the push pull connection kit for this spacer POWER MIG 300 drive rolls set too tight The tension arm should be set at 1 to 1 1 2 Push Pull torch drive rolls set too tight Refer to owners manual for If all recommended possible areas proper setting of misadjustment have been checked and the problem persists If pulse welding the trim value Contact your local Lincoln may be set too high Authorized Field Service Facility Clean or replace contact tip problem continues after a thru e are checked then the Stall Factor Number needs to be increased See Stall Factor Number Adjustment Wire bird nests while welding Torch liner conduit not inserted all the way so that it is touching the inner black plastic wire guide Inner black plastic wire guide is worn out Replace guide Push Pull torch drive rolls set too tight Refer to owners manual for proper setting problem continues after a thru c are checked then lower your Stall Factor Number See Stall Factor Number Adjustment A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Ser
36. S below 200 WFS POWER MIG 300 LINCOLN 5 B 12 OPERATION B 12 POWER MODE The Power Mode process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop outs or burning through For Aluminum welding it provides excellent control and the ability to maintain constant arc length This results in improved welding performance in two primary types of applications Short Arc MIG at low procedure settings Aluminum MIG welding Power Mode is a method of high speed regulation of the output power whenever an arc is established It provides a fast response to changes in the arc The higher the Power Mode Setting the longer the arc If a welding procedure is not established the best way to determine the Power Mode Setting is by experimenta tion until the desired output result is established In the Power Mode two variables need to be set Wire Feed Speed Power Mode Trim Setting up a Power Mode procedure is similar to set ting a CV MIG procedure Select a shielding gas appropriate for a short arc process For steel use 75 25 Ar CO shield gas For Stainless select a Helium blend Tri Mix For Aluminum use 100 Ar Start by setting the wire feed speed based upon mate rial thickness and appropriate travel speed Then adjust the Volts Trim knob as follows For steel listen for the traditional fryin
37. birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 hy h 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around
38. cable connector to PUSH PULL GUN Depending on the weld mode set the Voltage or Trim at the POWER MIG 300 using the right control knob located on the upper case front panel The Wire Feed Speed WFS is set using the control knob on the Torch The left control knob on the POWER MIG 300 is inactive The actual WFS being set at the torch is displayed on the POWER MIG 300 All weld parameters normally available for the active weld mode are available during push pull operation Refer to the Operation Section of this manual POWER MIG 300 LINCOLN amp D 1 MAINTENANCE E SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill e Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts GENERAL MAINTENANCE In extremely dusty locations dirt may clog the air pas sages causing the welder to run hot Blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on internal parts The fan motors have sealed ball bearings which require no service DRIVE ROLLS AND GUIDE PLATES After every coil of wire inspect the wire drive mecha nism Clean it as necessary by blowing with low pres sure compressed air Do not use solvents for cleaning the idle roll because it may wash the lubricant out of the bearing All drive rolls are stamped with
39. cked and the problem persists Increase wire feed speed to 350 Contact your local Lincoln 400 ipm Authorized Field Service Facility If problem continues after a thru d are checked then the Stall Factor Number needs to be increased See Stall Factor Number Adjustment While loading wire the wire bird 1 Check torch cable for kinks nests before the wire gets all the Torch cable should be laid out way through the torch relatively straight Make sure liner conduit is insert ed all the way into the rear wire drive so that it is up against the inner black plastic wire guide Inner black plastic wire guide is worn out Replace guide Slow down wire feed speed while pushing wire up through the liner Recommended setting 350 ipm Clean or replace contact tip A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER MIG 300 LINCOLN E 8 TROUBLESHOOTING 8 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION PUSH PULL WIRE FEEDING PROBLEMS While loading wire the wire bird 1 Straighten the first six inches of nests if the wire misses the outlet the wire before feeding it into the guide while shooting the gap
40. ctance negative numeric val ues By adding to the energy level the weld bead appear ance improves spatter levels decrease and wetting action at the toes of a fillet weld increases The arc is softer with the higher inductance setting and the arc lends itself to faster travel speed In GMAW P the pulsed spray mode of metal transfer the Arc Control is once again used to increase and decrease the focus of the energy delivered to the arc Increasing the setting in the range of 1 to 10 results in an increase in pulsed frequency and the effect is to narrow the arc cone and concentrate the available energy to a smaller area Decreasing the Arc Control setting from 1 to 10 results in a reduction of pulsed frequency the result is a broader arc cone which creates a wider weld bead Important to note here is that if a component of a pulsed waveform is increased then another must be decreased Adding pulsed frequency through an increase in the Arc Control setting then also results in a proportional decrease in background current If this were not the case then the arc would become too long with too much energy and the arc would be unusable TABLE B 2 Arc control settings by process PROCESS ARC CONTROL SYNONYM SETTING APPLICATION AND RESULT GMAW S Short circuiting metal transfer GMAW P Pulsed spray metal transfer Pulse on Pulse Aluminum Only Arc Force Inductance or Pinch Control Puls
41. distinct and the bead width increases In GMAW PP mode arc control adjusts the modulation fre quency which means the speed at which the ripples are produced in the weld See Pulse on pulse description later in this section When faster travel speeds are desired arc control needs to be set higher When slower travel speeds are desired arc control needs to be set lower The Arc control adjustment is selected by toggling the SELECT switch until the LED next to ARC CONTROL is lit The Arc control value will be displayed Arc control can be adjusted by toggling the SET switch up or down The default value is OFF Crater The crater is the end of the weld which normally solidifies creating a concave surface This can result in stresses that can cause cracks in the center of the crater The purpose of the Crater control is to fill up the crater so that its surface becomes flat Crater control in this machine is more efficient than in other machines Normally in other machines the crater filling pro cedure is a step down from the welding WFS to the crater filling WFS In this machine instead of a step down the tran sition is a ramp down which results in a more controlled fill ing up of the crater and so less stresses present in it The values to enter are first the desired time to stay at the Crater settings and the desired WFS and voltage trim to fill the crater The Crater timer is selected by toggling the SELECT sw
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43. e factory provided with the POWER MIG 300 CYLINDER may explode if damaged Gas under pressure is explosive Always keep gas cylinders in an upright position and always keep chained to undercarriage or stationary support See American National Standard Z 49 1 Safety in Welding and Cutting published by the American Welding Society Install shielding gas supply as follows 1 Set gas cylinder on rear platform of POWER MIG 300 Hook chain in place to secure cylinder to rear of welder 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth GUN HANDLE 5 GUN TUBE a 9 16 14 3mm SET SCREW LINER TRIM d LENGTH GAS DIFFUSER NOZZLE INSULATION GAS NOZZLE POWER MIG 300 LINCOLN 5 An INSTALLATION DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve outlet WARNING Be sure to keep your face away from the valve outlet when cracking the valve 4 Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench NOTE If connecting to 100 CO cylinde
44. e keine stromfiihrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR 7 amp nf dchsn zucct e E GUB MU S Oa EERTE ecu S422 Xe uc Bp e 2x9 Weal AMI d ous Quali Y O 1 gl uit celal AL usu DA dax Y Jio moe Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOOM EA Pam SEL IF eis A Jo ALD al gll pis Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HAUSHERMRELTTF ez 119 59 s ESSAI dise ule Lily vues al ad ne t daag READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER
45. ections are Weld Mode Process selection choices Preflow Postflow Run In Choice of weld parameters Start that can be adjusted Arc Control Complete descriptions of Crater each parameter are found Burnback later in this section Spot Only one LED will be illuminated at any time The Weld Mode attribute will always be a valid selection the other attributes may not be available in all processes 5A SELECT Toggle Switch This switch toggles through the 8 selections detailed above the switch A red LED is located next to each possible selection and is illuminated when that choice can be changed 5B Display Meter This meter displays the active weld mode a set of weld parameters that have been determined to pro vide the recommended results for a particular welding process when the Weld Mode LED is illuminated or when any one of the other seven LED s is illuminated the meter indicates what value that welding parame ter has been set to 5C SET Toggle Switch This switch adjusts up or down the value shown on the display meter When the WELD MODE LED is illu minated this switch is changing the weld mode of the machine The most commonly used modes are dis played in the chart on the right half of the Multi Process Panel If the LED next to a weld parameter Preflow Postflow Run In Start etc is illuminated the SET switch will adjust the setting of that specific weld
46. ed frequency control Pulsed frequency array control Lower 1 to 10 for low bu types of electrodes Higher 1 to 10 for cellulosic and other types Setting 1 to 10 for softer higher energy arc Setting 1 to 10 for a crisper lower energy arc Minus settings reduces frequency Plus settings increase frequency Minus settings result in lower array frequency and the plus settings increase the array frequency POWER MIG 300 LINCOLN 5 Minus settings are soft and buttery for low hydrogen electrodes Plus settings are harsh and digging for other types of electrodes The minus settings result a more fluid puddle and larger droplet size The lower settings reduce the droplet size and reduce energy to the arc Wider arc cone and weld bead Narrower arc cone and narrower weld bead Minus settings result in a wider bead with more distinct ripples Plus settings narrow the resultant bead and the ripples are less distinct B 7 OPERATION EY In the case of special waveforms designed for pulsed weld ing aluminum Pulse on Pulse the effect is similar to what occurs with standard pulse As the Arc Control is increased from 1 to 10 the frequency of the Pulse on Pulse array increases As the frequency increases the weld bead ripples become less distinct and the arc cone narrows When the Arc Control is set from 1 to 10 the Pulse on Pulse arrays decrease in frequency the weld bead ripples become more
47. en set screw of the connector on the back end of the gun 4 Insert the untrimmed Liner into the back end of the gun 5 Seat Liner bushing into back of gun Secure Liner by tightening set screw Do not install the gas dif fuser at this time 6 Lay the cable straight and trim Liner to 9 16 Remove burrs 7 Secure the gas diffuser into the tube 8 Tighten the set screw againstthe Liner CAUTION This screw should only be genily tightened Over tightening will split or collapse the liner and cause poor wire feeding FIGURE D 1 FEEDR END CABLE HANDLE INSULATION TUBE BRASS CABLE CONNECTOR 1 MOLDED GAS PLUG SET SCREW TIGHT AGIANST BRASS CABLE CONNECTOR CLAMPING SCREW LINER ASSEMBLY LINER BUSHING TO BE SEATED GUN HANDLE GUN TUBE m 9 16 14 3mm SET SCREW LINER TRIM LENGTH GAS up NOZZLE INSULATION GAS NOZZLE POWER MIG 300 LINCOLN E 1 TROUBLESHOOTING E 1 A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three ste
48. ersists Contact your local Lincoln Authorized Field Service Facility A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed POWER MIG 300 LINCOLN E 4 TROUBLESHOOTING ET Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FEEDING PROBLEMS Rough wire feeding or wire will not The gun cable may be kinked or twisted feed but drive rolls are turning The wire may be jammed in the gun cable or gun cable may be dirty Check drive roll tension and position of grooves Check for worn or loose drive rolls The electrode may be rusty or dirty Check for damaged or incorrect contact tip Check wire spindle for ease of rotation and adjust break ten If all recommended possible areas of misadjustment have been sion knob if necessary The wire feed stops while welding Check the wire feed drive rolls checked and the problem persists When trigger is released and pulled and motor for smooth operation Contact your local Lincoln again the wire feed starts Check for restrictions in the wire Authorized Field Service Facility feed path Check the gun and cable for restrictions Make sure gun liner and tip are correct for wire s
49. fined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b i SAFETY WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase
50. g the adjustable pressure arm down toward the back of the machine Lift the cast idle roll assembly and allow it to sit in an upright position 3 Remove the outside wire guide retaining plate by loosening the two large knurled screws 4 Twist the drive roll retaining mechanism to the unlocked position as shown below and remove the drive roll See Figure B 3 FIGURE B 3 5 Remove the inside wire guide plate 6 Replace the drive and idle rolls and inside wire guide with a set marked for the new wire size NOTE Be sure that the gun liner and contact tip are also sized to match the selected wire size 7 Manually feed the wire from the wire reel over the drive roll groove and through the wire guide and then into the brass bushing of the gun and cable assembly 8 Replace the outside wire guide retaining plate by tightening the two large knurled screws Reposition the adjustable pressure arm to its original position to apply pressure Adjust pressure as necessary WIRE REEL LOADING READI REELS SPOOLS OR COILS To Mount a 30 Lb 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter 1 Open the Wire Drive Compartment Door 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 3 Place the Optional Adapter on the spindle 4 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining ri
51. g and through the guide plates over the drive roll groove Pusha sufficient wire length to assure that the wire has fed into the gun and cable assembly without restriction Reposition the adjustable pressure arm to its origi nal position to apply pressure to the wire 4 Press gun trigger to feed the electrode wire through the gun IDLE ROLL PRESSURE SETTING The idle roll pressure adjustment knob is set at the factory at the 2 hash mark This is an approximate setting The optimum idle roll pressure varies with type of wire wire diameter surface conditions lubri cation and hardness As a general rule hard wires may require greater pressure and soft or aluminum wire may require less pressure than the factory set ting The optimum idle roll setting can be determined as follows 1 Press end of gun against a solid object that is elec trically isolated from the welder output and press the gun trigger for several seconds 2 If the wire birdnests jams or breaks at the drive roll the idle roll pressure is too great Back the adjustment knob out 1 2 turn run new wire through gun and repeat above steps 3 If the only result was drive roll slippage loosen the adjustment knob on the conductor plate and pull the gun cable forward about 6 15 cm There should be a slight waviness in the expose wire If there is not waviness the pressure is too low Tighten the adjustment knob 1 4 turn reinstall the gun cable and repeat
52. g egg sound of a good short arc MIG procedure to know you have the process set correctly For aluminum simply adjust the Volts Trim knob until the desired arc length is obtained Note the Volts Trim display is simply a relative number and DOES NOT correspond to voltage Some procedure recommendations appear in Table BA Recommended Welding Procedures for Power Mode Table B 4 MATERIAL X Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel WIRE E4043 E5356 L56 L56 L56 L56 L56 E308L E308L WIRE SIZE 0 035 0 035 0 025 0 025 0 030 0 030 0 035 0 035 0 030 0 035 GAS 100 Ar 100 Ar 100 CO 75 25 Ar CO 100 75 25 Ar CO 100 CO 75 25 Ar CO Tri mix Tri mix 22 Not Recommended 100 0 8 Not Recommended 90 1 0 20 120 1 0 120 1 0 100 0 7 100 1 0 80 1 5 50 0 5 18 ga 140 1 7 140 1 5 110 1 5 110 1 5 100 2 5 100 2 5 110 2 0 110 2 0 5 9 16 190 2 0 190 2 0 125 2 0 125 2 0 125 3 0 125 3 0 140 2 5 130 2 7 x 14 400 20 400 12 5 260 3 0 260 3 0 160 2 3 160 2 3 160 3 8 160 3 5 210 3 0 190 3 5 5 12 330 5 0 330 4 5 230 3 5 230 3 5 200 5 0 200 4 5 270 5 0 230 6 0 lt gt 10 ga 500 7 0 500 7 0 300 6 0 300 6 0 240 6 5 24017 0 325 6 5 300 7 0 316 570 9 0 600 7 8 400 17 5 400 7 0
53. he two hot lines with super lag type fuses as shown in the following dia gram The center contact in the receptacle is for the grounding connection A green wire in the input cable connects this contact to the frame of the welder This ensures proper grounding of the welder frame when the welder plug is inserted into the receptacle POWER MIG 300 LINCOLN 5 CONNECT TO A SYSTEM GROUNDING WIRE SEE THE UNITED STATES NATIONAL ELECTRICAL CODE AND OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUNDING CONNECT TO HOT WIRES OF A THREE WIRE SINGLE PHASE SYSTEM OR TO ONE PHASE OF A TWO OR THREE PHASE SYSTEM A 4 INSTALLATION ve GUN AND CABLE INSTALLATION A Magnum 300 gun and 15Ft 4 6m cable 12Ft 3 7m for Codes 11000 and below are provid ed with the POWER MIG 300 A Magnum cable liner for 035 045 0 9 1 2 mm electrode and contact tips for 035 0 9mm and 045 1 2mm are included for 15Ft WARNING Turn the welder power switch off before installing gun and cable LINER INSTALLATION AND TRIMMING INSTRUCTION SEE FIGURE 1 Remove the gas nozzle 2 Remove the gas diffuser from the gun tube If gas diffuser contains a small set screw loosen the set screw 3 Lay gun and cable out straight on a flat surface Loosen set screw of the connector on the back end of the gun 4 Insert the untrimmed Liner into the back end of the gun 5 Seat Liner bushing into back of gun Secu
54. i Process Panel The Display meter on the Multi Process Panel will indicate the run in speed Do not use the Output Control Knob on the upper case front to adjust the WFS This will change the welding WFS displayed in the meters on the upper case front The default value for Run In is OFF Run In speed is adjustable from 50 ipm to 150 ipm Inches per Minute Start Procedure This machine provides the option of setting a Starting Procedure to start the weld and from there to ramp to the welding procedure over a specified amount of time Typically starting on a higher starting procedure than the welding procedure is known as a Hot Start Setting a start ing procedure lower than the welding procedure is known as a Cold Start For SMAW Stick welding setting a Hot Start helps to minimize stubbing the electrode For GTAW TIG welding setting a Cold Start minimizes burn through of thin materials when not using a manual amperage control For Wire Feed welding using a start procedure can help improve starting characteristics A good example is when welding aluminum Aluminum s high thermal conductivity results in heat spreading around the plate very fast Therefore more energy is necessary at the very beginning to heat up the starting point of the weld Once the welding begins it is not necessary to give this extra heat anymore so a ramp down to the welding procedure is necessary To set a Start Procedure begin by usi
55. ided Includes upper and lower cylinder supports wheel axles and mounting hardware ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES The following Magnum 300 gun and cable assemblies are separately available for use with the POWER MIG 300 Each is rated 300 amps 6096 duty cycle or 300 amps 4096 duty and is equipped with the integrated connector twist lock trigger connector fixed nozzle and insulator and includes a liner diffuser and con tacttips for the wire sizes specified 10 3 0 m 12 3 6 15 4 5 035 045 0 9 1 2 mm MAGNUM GUN CONNECTION KIT Optional K466 6 Using the optional K466 6 Magnum Connection kit for the POWER MIG permits use of standard Magnum 200 300 or 400 gun and cable assemblies K1692 2 SPOOL GUN PRINCE XL When the POWER MIG Gun Selector Switch is in the Standard Spool Gun position the POWER MIG pro vides gun trigger switch transfer between the Magnum gun or the spool gun for the same polarity welding with different wire and gas processes CAUTION Closing either gun trigger will cause the electrode of both guns to be electrically HOT Be sure unused gun is positioned so electrode or tip will not contact metal case or other metal common to work Because the control circuitry senses each gun through its trigger leads weld parameters are displayed and adjustable for the last gun that was triggered 1 Pulling the trigger for the built in feede
56. irable and the lower end of the Arc Control suits these types of electrodes In either case the arc con trol is available to increase or decrease the energy level delivered to the arc In GMAW S the short circuiting mode of metal transfer the Arc Control features the ability to increase or decrease the energy level at the arc Setting the arc control from 1 to 10 decreases energy and setting the Arc Control from 0 to 10 increases the energy delivered to the arc Solid carbon steel electrodes in a range from 025 045 6 mm 1 1 mm are nominally used and the shielding gas blend for GMAW S is usually 10096 carbon dioxide or a blend of argon and carbon dioxide The Arc Control in this scenario is set to control the droplet size and more pinch is added increasing pinch reduces energy to the arc to achieve the bacon frying sound associated with this mode of metal transfer Carbon steel electrodes employed in GMAW S usually per form best when the droplet size is regulated by pinch to reduce the droplet size transferred with each short circuit event When welding with solid stainless steel types of electrodes it is usually desirable to increase the energy delivered to the arc High percentage argon blends with a 2 addition of oxygen or a three part shielding gas blend comprised of 90 Helium 7 5 Argon 2 5 carbon dioxide are usu ally employed The added energy is associated in this sce nario with increasing the indu
57. itch until the LED next to CRATER is lit and flashing A crater time may be set using the SET switch The available values for crater control time go from Off to 0 1 seconds and from there to 10 0 seconds in incre ments of 0 1 seconds The Crater function offers the ability to set an endpoint for WFS and Voltage that will be reached over a specified time period At the end of the weld when the trigger is released the crater timer will begin and the WFS and Volts settings will ramp down from the Weld Mode WFS and Voltage settings to the Crater WFS and Voltage set tings over the time selected This creates a ramp down of the WFS and Volts during the Crater time In the GMAW FCAW and Power weld modes crater WFS and voltage are adjustable using the control knobs on the upper case front This in indicated by the flashing LED s next to WFS and VOLTS n the GMAW P weld modes Crater WFS and trim are adjustable This is indicated by the flashing LEDs next to WFS and TRIM Burnback Setting the Burnback means setting the adjustable time delay between turning off the wire feeding and turning off the arc Burnback helps to prevent wire sticking to the pud dle The Burnback feature will allow current to continue to flow for a specified time period at the end of a weld after wire feeding has stopped The Burnback timer will be selected by toggling the SELECT switch until the LED next to BURNBACK is lit A burnback
58. ize being used Make sure drive rolls and guide plates are clean and are the correct size Check spindle for ease of rotation CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed POWER MIG 300 LINCOLN e TROUBLESHOOTING ES Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION GAS FLOW PROBLEMS Gas does not flow when gun trigger 1 Make sure gas supply is con is pulled nected properly and turned on If the gas solenoid does actuate click when the gun trigger is If all recommended possible areas pulled there may be a restriction of misadjustment have been in the gas supply line checked and the problem persists Contact your local Lincoln The gun cable assembly may be Authorized Field Service Facility faulty Check or replace If gas solenoid does not operate when gun trigger is pulled the problem is within the POWER MIG 300 Make sure the gun is pushed all the way into gun mount and is properly seated A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance befo
59. mplete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page INSTA AMON Section A Technical Specifications A 1 Safety Precautions ne aan ta aient D oues A 2 Uncrating the POWER MIG 300 in A 2 oci A 2 Input Power Grounding and Connection Diagrams sse A 2 A 3 Gun and Cable Installations e ert ine idee de A 4 Shielding 4 thru 5 Section B Safety Precautions diene dei ned etr ELT ere aes B 1 Definition Of Welding Modes B 1 Common Welding Abbreviations esses nennen B 1 Product DOSCHIDUON e a B 2 Controls and Settings
60. ne is in the Hold period Output adjustment while in the Hold period results in the prior to operation characteristics stated above After the 5 second Hold period the meter dis plays the set Voltage GMAW FCAW or Trim GMAW P value CC Processes The meter displays the status of the output When output is enabled the meter will display ON When there is no output the meter will display OFF 3 OUTPUT CONTROLS The POWER MIG 300 has 2 encoder knobs to adjust weld parameters Each encoder changes the displayed value of the meter located directly above that encoder e In CC GTAW modes the left encoder sets the maxi mum welding current Full depression of a foot or hand amptrol results in the preset level of current In CC Stick and CC GTAW the right encoder activates and de activates the output Turning the encoder clock wise enables the output if not using a remote trigger device To de energize the output turn the encoder counter clockwise The display above will indicate the ON or OFF status of the output 4 THERMAL This status light illuminates when the power source has been driven into thermal overload OPERATIONS aa 5 MULTI PROCESS PANEL This panel enables selection of weld modes as well as adjustment of certain weld parameters within each weld mode The eight discrete LED s are used to identify which selec tion will be shown on the display The possible sel
61. ng gas to flow after the trigger is pulled and prior to wire feeding and establishing an arc The Postflow setting allows a time to be selected for shielding gas to continue to flow after the trigger is released and output current is turned off The Preflow timer will be selected by toggling the SELECT switch until the LED next to PREFLOW POSTFLOW is lit The display meter will read Pre The present Preflow time will be displayed and can be changed by positioning the SET switch up or down The Postflow timer will be selected by pressing down the SELECT switch an additional time The LED next to PREFLOW POSTFLOW will remain lit but the dis play meter will now read Pos The present Postflow time will be displayed and can be changed by position ing the SET switch up or down The default value for both Preflow and Postflow is OFF 0 seconds Preflow can be adjusted from 0 to 2 5 seconds in 0 1 second increments Postflow can be adjusted from 0 to 10 0 seconds in 0 1 second increments Run In The Run In function offers the ability to set a wire feed speed from trigger until an arc is established that is inde pendent of the Welding or Start wire feed speed Setting a Run In WFS lower than the welding WFS avoids stubbing problems when starting the arc Run In is selected by toggling the SELECT switch until the LED next to RUN IN is lit A Run In WFS may be adjusted using the SET switch on the Mult
62. ng groove on the spin dle 5 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 6 Position the Readi Reel so that it will rotate in a direc tion when feeding so as to be de reeled from top the of the coil 7 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 8 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 9 Slide cage all the way onto the adapter until the retaining spring pops up fully CAUTION Check to be sure the retaining ring has fully returned to the locking position and has securely locked the Readi Reel cage in place Retaining spring must rest on the cage not the welding electrode 10 To remove Readi Reel from Adapter depress retain ing spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle FIGURE B 4 2 IN O D SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR INSIDE CAGE WIRES RELEASE BAR TO MOUNT 10 to 44 Lb 4 5 20 kg SPOOLS 12 300 mm Diameter or 14Lb 6 Kg Innershield Coils GROOVES READI REEL For 13 14 6 Kg Innershield coils K435 Coil Adapter must be used 1 Open the Wire Drive Compartment Door 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 3 Place the spool on the spindle
63. ng the SELECT switch to select the Start LED Using the SET switch enter the desired Start ramp time duration its available values range from 0 01 seconds to 0 50 seconds in increments of 0 01 seconds or the default value of OFF This value will be dis played on the digital meter of the multiprocess panel See Figure B 2 After setting the Start time also set the WFS and voltage trim The way to know what information needs to be entered is to look for flashing LED s If an LED is flashing that parameter value needs to be entered POWER MIG 300 LINCOLN B 6 OPERATION B 6 Arc Control See Table B 2 There are no specific unit values offered because the setting of this feature largely depends upon operator preference Arc Control has a different effect on the character of the arc depending upon the welding process applied In SMAW STICK mode arc control adjusts the arc force It can be set to the lower range for a soft and less penetrating arc characteristic negative numeric values or to the higher range positive numeric values for a crisp and more pene trating arc Normally when welding with cellulosic types of electrodes E6010 E7010 E6011 a higher energy arc is required to maintain arc stability This is usually indicated when the electrode sticks to the work piece or when the arc pops out during manipulative technique For low hydrogen types of electrodes E7018 E8018 E9018 etc a softer arc is usually des
64. oceed POWER MIG 300 LINCOLN 8 Jequunu epoo eu BAIN 104 si au sjaued y euo uo episul pejsed si epoo sejnomed jenueui siy Aq eq jou AjUO JO S SIUL ALON F 1 054 osr 8 30S ALAYI 319143933 13NVd HV3H WO NMOHS SIN3NOdAOO 1NOH3 350 TV SIYOHI 61 NHL 30 301S 1N8NOdIOO MAN SONSNOAS ALINVO 1 ENHANCED DIAGRAM F 1 g MOTISA M 9 aise se 31HM M HO Q33 H gt AVHO HODIOVIE 8 3409 40109 ava Lo HOUNS TINd HSNd INDO 0085 ANOHISVO NO 0311001 FER N 1777 NNO 8 Mains L Tha Hsnd beer 4 INNO 70085 Oog w au 38009N3 mou Yi cana xiu eun v 4 CEIHS GVOA YAddOHO V00
65. or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame
66. p procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER MIG 300 LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Major physical or electrical damage 1 Contact your local authorized is evident when the sheet metal Lincoln Electric Field Service covers are removed facility for technical assistance Input fuses keep blowing or input 1 Make certain
67. r insert regulator adapter between regulator and cylinder valve adapter is equipped with a plastic washer be sure it is seated for connection to the CO cylin der 5 Attach one end of the inlet gas hose to the outlet fitting of the flow regulator the other end to the POWER MIG 300 rear fitting and tighten the union nuts securely with a wrench 6 Before opening the cylinder valve turn the regula tor adjusting knob counterclockwise until the adjusting spring pressure is released 7 Standing to one side open the cylinder valve slow ly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully WARNING Never stand directly in front of or behind the flow regulator when opening the cylinder valve Always stand to one side 8 The flow regulator is adjustable Adjust it to the flow rate recommended for the procedure and process being used before making the weld POWER MIG 300 LINCOLN B 1 Read entire Operation section before operating the POWER MIG 300 WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground e Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable mate
68. r Mode welding processes later in this section Mode 5 and mode 6 are non synergic CV GMAW modes for bare and flux cored wires respectively In these modes the user presets the wire feed speed WFS on the left meter and the welding voltage on the right These two settings are independent that is if the WFS is changed the voltage will remain con stant or vice versa All of the other mode numbers designated as CV are synergic Again WFS is shown on the left meter and voltage is shown on the right meter However in using these modes the WFS is preset and the voltage is preset only once Now when the WFS is changed the voltage will change with it so that the arc appearance and arc length will stay the same without the necessity to re adjust the voltage The modes shown as GMAW P or GMAW PP are all synergic pulsed modes In these modes WFS is shown on the left meter and Trim is shown on the right meter The user adjusts WFS to obtain an arc with the correct arc energy for the material thickness being welded The Trim which is adjustable from val ues of 1 5 to 0 OFF and up to 1 5 controls the arc length Higher values of Trim give longer arc lengths Once the user has adjusted the Trim for one WFS the power supply will synergically change many variables so that as the WFS is changed the arc length and arc appearance will remain the same The synergic modes are usable with both push and push pull torches as
69. r gun Magnum 300 e Disables spool gun operation e Changes the displays of the POWER MIG 300 to correspond to feeder gun operation e Closing feeder gun trigger starts feeder gun weld ing and makes both electrodes electrically HOT 2 Pulling SPOOL GUN Trigger e Disables built in feeder gun operation Changes the displays of the POWER MIG 300 to correspond to Spool Gun operation e Closing spool gun trigger starts spool gun welding and makes both electrodes electrically HOT 3 Operation with POWER MIG 300 e Install the spool gun per the installation instructions e POWER MIG 300 input power ON Make sure that the Gun Selector Switch is in the Standard S pool Gun position Pull and release the trigger of the Spool Gun The Power Mig recognizes the spool gun as active and weld parameters are adjustable for welding with the S pool Gun POWER MIG 300 LINCOLN 5 2 ACCESSORIES 2 Non Synergic Weld Modes Mode 5 e Voltage is adjustable at the power source The right control knob on the power source will adjust the voltage that is displayed in the meter directly above it e The left Display WFS AMPS on the POWER MIG 300 will have 4 dashes to indicate that the left control knob on the power source is inactive Wire Feed Speed is set at the Spool Gun The following procedure settings for Aluminum 4043 can be used as initial settings for making test welds to determine final
70. re Liner by tightening set screw Do not install the gas dif fuser at this time 6 Lay the cable straight and trim Liner to 9 16 Remove burrs 7 Secure the gas diffuser into the tube 8 Tighten the set screw against the Liner CAUTION This screw should only be gently tightened Over tightening will split or collapse the liner and cause poor wire feeding FIGURE A 3 FEEDR END CABLE HANDLE INSULATION TUBE BRASS CABLE CONNECTOR MOLDED GAS PLUG SET SCREW TIGHT AGIANST BRASS CABLE CONNECTOR CLAMPING SCREW LINER ASSEMBLY LINER BUSHING TO BE SEATED GUN amp CABLE ASSEMBLY INSTALLED INTO THE POWER MIG 1 Unscrew knurled screw on the drive unit front end inside wire feed compartment until tip of screw no longer protrudes into gun opening as seen from front of machine 2 Insert the male end of gun cable into the female casting through opening in front panel Make sure connector is fully inserted and tighten knurled screw 3 Connect the gun trigger connector from the gun and cable to the mating receptacle inside the com partment located above the gun connection made in step 2 above Make sure that the key ways are aligned insert and tighten retaining ring SHIELDING GAS For Gas Metal Arc Welding Processes Customer must provide cylinder of appropriate type shielding gas for the process being used A gas flow regulator for or Argon blend gas and an inlet gas hose ar
71. re you proceed POWER MIG 300 LINCOLN 5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Fault Codes Description Misadjustment s Corrective Action Glitch on the primary over current fault interrupt possibly caused by noise or a signal level misc hardware fault 1 Check the machine ground If problem persists contact an authorized Lincoln Field Service Shop Self clearing as condition ceases Main CPU problem The DSP has detected a problem with the CPU Check the machine ground Glitch on the CAP heart beat interrupt possibly caused by noise or a signal level right at the trip threshold misc hardware fault 42 If problem persists contact an authorized Shop Motor overload average motor current exceeded 8 00 amps for more than 0 50 seconds Verify motor armature is not binding Verify Wire S pool is not binding Motor overcurrent average motor current exceeded 3 50 amps for Verify wire can move freely in cable Verify S pool Brake is not more than 10 0 seconds set to tight Displays Description Appears at power up while the machine is going through its self configu ration E rr HHH Fault code display The first fault to occur will be displayed for three seconds The display will cycle through fault codes for all faults that persist after the initial three second period are displayed for 1 sec ond each m Weld mode
72. rial away y Es Do not weld on closed contain ers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion De EZ Observe all safety information throughout this manual DEFINITIONS OF WELDING MODES NON SYNERGIC WELDING MODES A Non synergic welding mode requires all welding process variables to be set by the operator SYNERGIC WELDING MODES A Synergic welding mode offers the simplicity of single knob control The machine will select the cor rect voltage and amperage based on the wire feed speed WFS set by the operator OPERATION B 1 COMMON WELDING ABBREVIA TIONS WFS Wire Feed Speed cc Constant Current CV Constant Voltage GMAW MIG Gas Metal Arc welding GMAW P MIG Gas Metal Arc welding Pulse GMAW PP MIG Gas Metal Arc welding Pulse on Pulse GTAW TIG Gas Tungsten Arc welding SMAW STICK Shielded Metal Arc welding FCAW INNERSHIELD Flux Core Arc Welding POWER MIG 300 LINCOLN 5 B 2 OPERATION PRODUCT DESCRIPTION The POWER MIG 300 is a complete semiautomatic multi process DC arc welding machine offering CV and CC DC welding It is rated for 300 amps 32 volts at a 60 duty cycle The standard machine is equipped to weld CC Stick CC GTAW CV FCAW and synergic and non synergic CV GMAW GMAW P and Pulse on Pulse and Power Mode welding processes See the descriptions for Pulse on Pulse and Powe
73. rical Code and local code requirements This welder may be operated from a single phase line or from one phase of a two or three phase line 2 The POWER MIG 300 is supplied connected for 230 Volt Input If the welder is to be operated on another voltage it must be reconnected according to the instructions in Figure A 1 POWER MIG 300 LINCOLN 5 A 3 INSTALLATION n FIGURE A 1 Triple Voltage Machine Input Connections INPUT SUPPLY CONNECTION DIAGRAM BUE Disconnect input power before inspecting or servicing machine Do not operate with covers removed ELECTRIC SHOCK CAN KILL Only qualified persons should install use or service this equipment Do not touch electrically live parts Install and Ground machine National Electrical Code and local codes Use Grounding Stud or Lug inside Use CU wire only Consult Instruction Manual before installing or operating 524373 3 The POWER MIG is shipped with 10ft 3 05m input cable and plug connected to the welder FIGURE A 2 Receptacle Diagram Using the instructions in Figure A 2 have a quali fied electrician connect the receptacle or cable to the input power lines and the system ground per the U S National Electrical Code and any applica ble local codes See Technical Specifications at the beginning of this chapter for proper wire sizes For long runs over 100ft 30 48m larger copper wires should be used Fuse t
74. rs are detailed later in this section FIGURE B 2 BD woot wu rm f JA 1 crane BAI wor TABLE B 1 PREFLOW POSTFLOW POWER MIG 300 LINCOLN 8 B 5 OPERATION B 5 MULTI PROCESS PANEL FUNCTIONS Weld Mode Setting the Weld Mode is selecting the proper program from the ones available in the machine s memory for a particular welding application The table on the right side of the front panel See Figure B 2 gives information on the different programs available in this machine It describes the type of process CV CC synergic GMAW type of metal mild steel stainless steel alu minum type of shielding gas and size of electrode rec ommended for a particular mode The Weld Mode selection is enabled by toggling the SELECT switch until the LED next to Weld Mode is lit A Weld Mode number will be displayed on the display meter Toggling the SET switch up or down will increase or decrease the WELD MODE number displayed The machine will change to the selected weld mode after two seconds of SET switch inactivity If the SELECT switch is changed before two seconds of SET switch inactivity the machine will not change modes The last active Weld Mode will be saved at power down so that it will be selected with the next power up of the machine Preflow Postflow The Preflow setting allows a time to be selected for shieldi
75. ry the ripple spacing in the weld bead BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC Excellent appearance of the weld bead Improved cleaning action Reduced porosity Table 3 shows WFS and Trim settings for common aluminum types and wire sizes when welding with Pulse on Pulse The welds made to obtain the values in the table were fillet welds in the flat position The values in the table can be helpful as a starting point to establish a welding procedure From there adjust ments need to be made to set the proper procedure for each specific application out of position other types of joints etc The comments on Table B 3 show values of WFS below which it is not recommended to weld The rea son is that below these values the weld transfer will change from spray arc to a short arc which is not advisable when welding aluminum WELDING PROCEDURES FOR PULSE ON PULSE TABLE B 3 MATERIAL Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356 GAS 100 Ar 100 Ar 100 Ar 100 Ar WIRE E4043 E4043 E5356 E5356 WIRE SIZE 0 035 3 64 0 035 3 64 WELD MODE 98 99 101 102 14 ga 250 1 0 200 1 0 230 1 0 22511 0 4 E 82 10 400 1 0 280 1 0 425 1 0 400 1 0 22 s 3 16 550 1 0 340 1 0 670 1 0 500 1 0 1 4 600 1 0 400 1 0 700 1 0 550 0 9 COMMENTS Not Recommended Not Recommended Not Recommended Not Recommended below 200 WFS below 100 WFS below 200 WF
76. s blinking to indicate that the machine is in the Hold period Output adjustment while in the Hold period results in the prior to operation characteristics stated above After the 5 second Hold period the meter dis plays the set WFS CV modes or Amp CC modes value Figure B 1 CJ ECT M B Q DT POWER MIG 300 LINCOLN 5 B 3 2 VOLT TRIM METER This meter displays either the voltage or trim value depending on the status of the machine Located below the display is the text Volts and Trim An LED light is illuminated to the left of one of these in order to indicate the units of the value displayed in the meter CV Processes Prior to GMAW and FCAW operation the meter displays the desired preset Voltage value Prior to synergic GMAW P and GMAW PP oper ation the meter displays the desired preset Trim value Trim adjusts the synergic default voltage as a percentage of that voltage A trim value of 1 is the default and results in the recommended voltage setting for a given wire feed speed Adjusting trim to a value of 95 adjusts the volt age to 95 of the recommended voltage During Welding the meter displays actual aver age volts After welding the meter holds the actual voltage value for 5 seconds During this time the display is blinking to indicate that the machi
77. settings Wire Dia WFS Setting Arc Voltage In mm Spool Gun Seiting 030 8 mm 035 9 mm 3 64 1 2 mm 4 Synergic Weld Modes The POWER MIG 300 is designed to enable synergic weld modes and synergic pulse processes with the spool gun The actual wire feed speed WFS of the spool gun must be measured and manually set on the POWER MIG 300 as a work point for the POWER MIG 300 SPD e In synergic modes when the spool gun trigger is pulled an adjustable value for the SPD work point is displayed in the left meter The letters SPD are displayed in the right meter e The left control knob adjusts the SPD value The right control knob is inactive Measure the actual WFS in inches per minute at the spool gun and set the SPD at the POWER MIG 300 to match this value WFS can be measured by pulling the trigger of the spool gun and feeding wire for 6 seconds Measure the length of wire in inches that was fed and multiply by 10 The POWER MIG 300 is now configured and ready to weld in the synergic mode Adjustment of the SPD value from the set value has the affect of adjusting trim or arc length To increase the arc length increase the SPD value atthe POWER MIG 300 to a value higher than the actual WFS Remember do not change the WFS at the spool gun To decrease the arc length decrease the SPD value at the POWER MIG 300 to a value lower than the actual WFS Remember The dialed in SPD value
78. time may be set using the SET switch The default value is OFF 0 seconds Burnback time is adjustable from 0 to 0 25 seconds in 0 01 second increments Spot The Spot Timer adjusts arc on time for spot or tack welds With the Spot feature active Spot time selected when the trigger is pulled and the arc is established the weld will continue until the expiration of the spot timer and the next active state will be enabled crater or burnback The trigger must be released and pulled again for another Spot cycle The Spot timer is selected by toggling the SELECT switch until the LED next to SPOT is lit The present SPOT time will be displayed and can be changed by toggling the SET switch up or down The default value is OFF 0 seconds Spot can be adjusted from 0 to 10 0 seconds in 0 1 sec ond increments WIRE DRIVE ROLL The drive rolls installed with the POWER MIG 300 have two grooves one side for 030 0 8mm solid steel electrode and the other for the 045 1 2mm electrode The actual drive roll size is stenciled on the side opposite of its groove If feeding problems occur a check may be required to make sure that the wire size and the drive roll size matches See Procedure for Changing Drive Rolls in this section POWER MIG 300 LINCOLN B 8 OPERATION B 8 PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS 1 Turn off the power source 2 Release the pressure on the idle roll by swingin
79. u solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place
80. uel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c
81. vice Facility for technical troubleshooting assistance before you proceed POWER MIG 300 LINCOLN 5 E 10 TROUBLESHOOTING E 10 Observe all Safety Guidelines detailed throughout this manual PUSH PULL WIRE FEEDING PROBLEMS STALL FACTOR an adjustment on the POWER MIG 300 that allows the welder to adjust the maximum amount of power going to the rear drive motor The purpose is to send only enough power to the rear drive motor to pull the wire off the spool and get the wire up the torch liner STALL FACTOR NUMBER ADJUSTMENT 1 Turn the POWER MIG 300 off 2 Hold the P ush Pull Torch trigger in and turn the power back on Continue to hold the trigger in while machine powers up 3 Once the machine displays SF in the left display and a number 5 to 35 in the right display the trigger can be released 4 Use the volts trim knob to adjustthe Stall Factor Number Once the Stall Factor Number is adjusted push the select switch up 6 The display should scroll the word SAVEd if the number was changed The display will scroll no CHANGE if the SF number was not changed The machine should automatically switch back to normal operation after it is done saving SF number CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you pr

Lincoln Electric IM736-D User's Manual

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