Lincoln Electric IM555 User's Manual
Contents
1. as e ee ternas eet A 2 LOCATION Site Pre A 2 MOUNTING BRACKETS nianna a a a a a R N A 2 HIGH FREQUENCY INTERFERENCE PROTECTION suisses A 2 ELECTRICAL INPUT CONNECTIONS sseeee eee eene enenennnee nnne rennen enn s A 2 MACHINE GROUNDING i a senten na ese etna nas ese nna A 2 SUPPLY CONNECTIONS iii rececneneeeescnnne ee ee eter ases eterna asse e tnr Eann naana A 2 CONNECTION TO A V 300 terio teer nee tote tese toe Pete tete a tee vede nt A 2 CONTROL CABLE CONNECTION eene nnne en nennen 2 OUTPUT CABLES FOR PULSE WELDING eene A 3 USE WITH THE n n a a iiS A 3 CONNECTING A SBOOE GUN 3x e rte Mn Pe E nett A 3 OPERATION Section B SAEETY PREGAUTIONS 5 a e ee EE EU ES B 1 GENERAL DESCRIPTION sesseeeeeenenn eene rennen ntn nere na e e eren nad nenene B 1 RECOMMENDED PROCESSES AND EQUIPMENT su B 1 OPERATIONAL FEATURES AND 5 B 1 DESIGN FEATURES AND 5 B 2 WELDING CAPABILITY eee enn enne nmennnnnee nne nnrnn ennt nna tenet nine enn tnn B 2 LIMITATIONS a a t ere B 2 V300 SETMINGS tec ER B 3 MIG PULSER CONTROLS AND SETTINGS seen nennen B 3 OPERATION GUIDELINES issues eene nmn nennen entere eret B 32. 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 o los electrodos bajo carga con la piel o ropa moja da 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 9 Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden Nao toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pe a e terra 9 REPOR 7 amp nfdcosn izuect 97 12 pri ATUBS ELTFEL DEBRERAR e e E C EUST PERS SHEER Xe SH uc zz SU M x nig e sj HIE 453 ula gu us Qo qi 6 sl wal ye 9 paul dla ay ASI ils tal AI haila DE dias ule Ye ua 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 e Mantenha inflam veis bem guarda dos e naeduveo6 008 coste i A 9 RH m SE LIFE AT 9554 282 He AIX ule de Jamo ALD Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo
3. Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo e H HAUSHERMRELTTF 115 CMRI HRABGHREAR ez 9 Bo SSIs 8 ESSAI ER due le Al 5 usas cil gal ce aua g READ AND UNDERSTAND THE M ANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER 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 COM PRENEZ 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 9 Mantenga la cabeza fuera de los humos Utilice ventilaci n o 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 f r gute Be und Entl ftung des Arbeitsplatzes
4. A e Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous 23 40 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone rH WELDING SPARKS can cause fire or 7 explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn 4 Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual NM E GENERAL DESCRIPTION The MIG Pulser is a hand held pendant type GMAW Pulsing option for the V300 Pro and V300 I power sources It is a simple easy to use unit with a mini mum of controls It supports the GMAW P pulse MIG process on mild steel stainless steel and aluminum The MIG Pulser is supplied with a cable and brackets for connection and mounting to a V300 An optional control cable extension is also available which allows the MIG Pulser to be placed up to 25 feet from the V300 RECOMMENDED PROCESSES AND EQUIPMENT The MIG Pulser V300 combination can run the follow ing processes GMAW P 035 steel 100 700 IPM 90 10 Ar CO 045 steel 75 400 IPM 90 10 Ar CO 035 stainless steel 100 700 IPM 98 2 Ar O 045 stainless steel 75 350 IPM 98 2 Ar O 3 64 5356 Aluminum 150 600 I
5. RETURN TO MAIN MENU IM555 MIG PULSER Mach 1999 For use with machines having Code Numbers 10213 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MAN UAL AND THE SAFETY PRE CAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful e OPERATOR S MANUAL EEE SS LINCOLN je World s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors 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 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A For Diesel Engines Diesel engine exhaust and For Gasoline Engines The engine exhaust from some of its constituents are known to the State this product contains chemicals known to the of California to cause cancer birth defects and State of California to cause cancer birth defects other reproductive harm or other reproductive harm ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD
6. WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO it is BIR Chinese LEIA E COMPREENDA AS INSTRUC ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EM PREGADOR SRM OBO X HD OHBRBEE lt K HMA ETHBRMLTK EW EL THHORERME HST FEU ER ET 18 BE RC 58 AOE MR 88 D DR RE EX 8 FH RRR ST EZ BUR BO 09 EL OR E IDE e aol ool AQANANE SIBAT HA SHIRE PSI BHC Saal cal al gl aul y yai Jud al alati Gail guet caulas agil g acts i
7. LINCOLN E 1 DIAGRAMS WIRING DIAGRAM MIG PULSER E 1 846168 d S1O8NAS 1V914193 1002 SNIHO 109 va 3d NO YOLOANNOO 40 MIA WP Ba SII HOLOJNNOO NI Nid SIHL 3 IdNVX3 Oo O WOIGAW dNV AYJd 15 9 cr V109 OY SdNV GNNOYDYOVE es fic to your Note This diagram may not be totally applicable to every code covered by this manual The diagram speci machine is pasted inside one of the enclosure panels MIG PULSER JAN97 LINCOLN E LINCOLN ELECTRIC SERVILE MANUALS Now Available The following Service Manuals Extensive Troubleshooting ORDER FROM Lincoln Electric Company 22801 St Clair Ave Cleveland Ohio 44117 1199 LINCOLN amp These are comprehensive single sources of information relative to Installation Operation Maintenance Accessories Theory of Operation Replacement Parts Electrical Diagrams and Technical Service Group Customer Service Dept All orders must be pre paid US Funds Only Please allow up to 4 weeks for delivery Make checks or Money Orders payable to the Lincoln Electric Company Qty Titles Machine Codes Manual
8. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Step 3 RECOMMENDED COURSE OF Look under the column labeled PROBLEM ACTION SYMPTOMS This column describes pos sible symptoms that the machine may exhib f you have exhausted all of the items in step it Find the listing that best describes the 2 Contact your Local Lincoln Authorized symptom that the machine is exhibiting Field Service Facility Symptoms are grouped into the following categories engine problems function prob lems and output problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed n general these tests can be conducted with out removing the case wrap around cover 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 tr
9. CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 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 3 S may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts
10. PULSE WELDING PROCEDURE GUIDELINES issus 4 MAINTENANCE ices iiia cono iis c cu en Section C TROUBLESHOOTING ooi sesion e aec iran sevi RR Oc re van enr Oc ER de de Eae Uo aai Section D DIAGRAMS in Section E WIRING DIAGRAM EUMD E 1 PARTS LAU TM P 273 Series MIG PULSER JAN98 LINCOLN A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS MIG PULSER INPUT Modei Description vous Amps Frequency K954 1 MIG Pulser 42 VAC 1A 50 60Hz OUTPUT Output Frequency Peak Current Background Current Range Settings Settings 20 to 300 Hz 250 325 or 400 40 or 80 A PHYSICAL DIMENSIONS WEIGHT 3 Ibs 1 4 kg without cables 178 mm OPTIONS ACCESSORIES K955 25 25 ft 7 5m Control Cable Extension EXISTING CASE TOP SCREWS EXISTING CASE TOP SCREWS UNIVERSAL BRACKET 1 6 N MOUNTING HOLES TO as amp SECURE TO GENERIC p e HOOK BRACKET Frans 6 SURFACE ENCLOSED RUBBER BUMBER AND SCREW f 6 j E d 9 Figure A 1a Hook Bracket Installation for Figure A 1b Universal Mounting Bracket mounting to a V300 Power Installation for mounting to a Source generic surface MIG PULSER LINCOLN amp A 2 INSTALLATION A 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only q
11. 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above 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 WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page UBER i iv INS TAL ATION EI Section A TECHNICAL SPECIFIGATIONS tects e teres eere eee tee eei eee vou des ted eva Eee cedes ae A 1 SAFETY PRECAUTION G a a ai a a nennen
12. 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 coversand devices in posi tion 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 1 e In some cases it may be necessary to remove safety do id 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 d 2 Never coil the electrode lead around your body 14 Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running es 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right si
13. 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 Also see item 1 b ARC RAYS can burn 4 8 Use a shield with the proper filter and cover A plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 sp
14. 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 met allique 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 defonc tionnement 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 soud er 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 ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quan
15. the V300 the 14 pin Pulser plug can be connected to the lower 14 pin socket on the DC TIG STARTER which is labeled connect to WIRE FEEDER Switch to control at wire feeder to transfer control to the MIG PULSER The MIG PULSER cannot be used for TIG welding JAN97 LINCOLN amp A 3 INSTALLATION A 3 If the optional 25 foot Control Cable Extension is used it should be plugged into the 6 pin receptacle of the wye adapter and then into the MIG Pulser Only one Control Cable Extension should be used do not series multiple extensions together Using 50 foot or longer control cables will cause the signals traveling between the V300 and the MIG Pulser to degrade leading to poor welding performance NOTE The voltage meter on the wire feeder will not display voltage due to the lack of a 21 lead in the feed er connection OUTPUT CABLES FOR PULSE WELDING Pulse welding generates high peak currents which in turn cause large voltage drops in welding cables It is essential that large cables 2 0 minimum are used and that all connections are clean and tight Because of voltage drops the total length of the weld ing leads work lead length plus electrode lead length should not exceed 50 feet If longer cables are used the maximum achievable output voltage will be reduced NOTE Do not coil the output cables around any metal object USE WITH THE LN 9 GMA Using the MIG PULSER with a LN9 GMA requires installation of
16. the voltage board bypass jumper Other adapters as called for in the V300 manual are not needed for this usage but can be left in if already pre sent Problems with the trigger interlock may be experienced when using the MIG PULSER with an LN 9 GMA which has a L7265 2 Power PC Board If needed replace with the latest Power PC Board available CONNECTING A SPOOL GUN Refer to Figure A 3 for information about connecting a spool gun in conjunction with the MIG PULSER SET UP INSTRUCTIONS INVERTEC SWITCHES amp CONTROLS 1 eine SWITCH n d a Q 2 SET OUPUT CONTROL SWITCH TO REMOTE 3 SET METER POLARITY SWITCH TO d ON BACK OF V300 5 CABLE CONNECTIONS WYE CONNECTOR EXISTING FEEDER CABLE I V300 MIG PULSER WIRE FEEDER CODE THE LINCOLN ELECTRIC CO No CLEVELAND OHIO U S A SERIAL No 522163 Figure A 2 Control Cable Connection CABLE CONNECTIONS K493 10 CONTROL CABLE SPOOL GUN MODULE K488 SPOOL GUN K487 25 WYE CONNECTOR Figure A 3 Spool Gun Connection Diagram MIG PULSER JAN97 LINCOLN amp B 1 OPERATION B 1 SAFETY PRECAUTIONS Read entire section before operating this unit Additionally read the V300 operators manual before operating this unit A WARNING ELECTRIC SHOCK can kill
17. 9 Mantenha seu rosto da fuma a Use ventilac o e exhaust o para remover fumo da zona respirat ria KJUT F v 9 fsPBHEICTAESUCFEU 9 15 EUR Fa fE FEES e zzv SH7IAE ejsHAS e 2511919 SHAS MAS 518 FARAH 587E ASIA Clea oe lue dlui 9 co Gal bacs ga Ar ggill arin 9 Li adit ui AMA Ge gaah ys Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas XVFFYA H EAKLRU PD PSB ETBRAL Fe DF ITF e Hs BIS BLEUS Gb J uit s jus e 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 e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas OSZD ERAL EEE THHIRIFE L EUTFEL CHRRKTARRARS ERR EIE E e ao Sel eee Asal oA Aga cus 11 Juli 114 Qui Y e ae Cut All gl Aral
18. PM Ar The MIG Pulser V300 combination can be used with all wire feeders recommended for the V300 LN 25 LN 7 family It will also work with the Magnum Spoolgun with limitations No other options or accessories are required or supported Note Using the MIG PULSER with a LN9 GMA requires installation of the voltage board bypass jumper on the LN9 OPERATIONAL FEATURES AND CONTROLS The MIG Pulser has the following controls as standard Arc Length continuously variable Peak Current choice of Low Medium and High and Background Current choice of Normal and High MIG PULSER LINCOLN B 2 OPERATION B 2 DESIGN FEATURES AND ADVANTAGES Simple controls make this unit easy to set up and adjust The control algorithm is adaptive it responds to changes in stick out and gun angle while maintaining a stable arc Designed to the IEC 974 1 standard Attractive rugged case includes carrying handle and rubber feet Unit is supplied with one bracket for mounting to the V300 and one universal bracket for mounting to ver tical or horizontal surfaces WELDING CAPABILITY The V300 must be derated when used for GMAW P with the MIG Pulser High peak currents required by the pulse process increase the power source heating thus reducing the rated output The V300 Pro and V300 I with three phase input are presently rated 300 amps at 6096 duty cycle When pulsing the ratings of both models must be reduced to 250 a
19. Power without MIG Pulser 3 Phase 50 Hz 1 Phase 50 Hz JAN97 300 Amps 60 Duty Cycle 250 Amps 60 Duty Cycle 300 Amps 60 Duty Cycle 200 Amps 6056 Duty Cycle V300 PRO Rating when Using MIG Pulser 250 Amps 60 96 Duty Cycle 200 Amps 60 Duty Cycle V300 I Rating when Using MIG Pulser 250 Amps 60 96 Duty Cycle 150 Amps 6096 Duty Cycle MIG PULSER LINCOLN B 3 OPERATION B 3 V300 SETTINGS Read and understand the V300 Instruction Manual before attempting to use the V300 MIG Pulser system Also refer to figure A 2 in the Installation chapter The V300 must be set to the TIG Mode when using the MIG Pulser This is because pulse welding is a current controlled process not a constant voltage process like straight GMAW By using the GTAW position the V300 is placed in a current control mode and the Arc Force Inductance control is made inactive The Wire Feeder Voltmeter Switch on the back of the V300 must be set to the position normally called the electrode negative position although the MIG Pulser is used for electrode positive welding The setting allows the MIG Pulser to sense arc voltage The V300 Local Remote Switch must be set to Remote Control This allows the MIG Pulser to control the V300 output The Output Control on the V300 is not func tional in the Remote Control mode Other V300 settings should be made according to the installation conditions and the wire feeders use
20. SER for Stainless These settings were developed for joints in the flat or Steel and Mild Steel These settings are intended as horizontal position Out of position work will require suggestions only The serviceability of a product or adjustments to these procedures structure utilizing this type of information is and must be the sole responsibility of the builder user Many To tighten or stiffen the arc try decreasing the Peak variables beyond the control of The Lincoln Electric setting To widen or soften the arc try increasing the Company affect the results obtained in applying this Peak setting Table B 2 Procedure Guidelines for Stainless Steel 035 E308LSi 98 2 Ar O5 045 E308LSi 98 2 Table B 3 Procedure Guidelines for Mild Steel 035 L 56 90 10 2 045 L 56 90 10 2 JAN97 MIG PULSER LINCOLN C4 MAINTENANCE C 1 GENERAL MAINTENANCE No regular or periodic maintenance is required for the MIG Pulser As with any welding equipment occa sionally clean the exterior of the unit with a low pres sure airstream or a damp cloth This keeps the front and rear nameplates in a readable condition Replace any nameplates that become illegible MIG PULSER LINCOLN D 1 TROUBLESHOOTING D 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel
21. Unit Price Total Price Square Wave Tig 255 Codes 10022 10134 SVM100 A 45 00 V300l Codes 9826 10133 SVM101 A 45 00 SP100 Codes 9284 10050 SVM102 A 45 00 Power Arc 4000 Codes 10083 SVM103 A 45 00 Power Arc 4000 Codes 10200 10244 SVM103 B 45 00 ProCut 60 Single Phase Codes 9819 10118 SVM104 A 45 00 V300 PRO Codes 9934 10131 SVM105 A 45 00 LN 7 GMA Codes 9168 9931 SVM106 A 45 00 RANGER 8 Codes 9972 10110 SVM107 A 45 00 DC600 Codes 9773 9910 SVM108 A 45 00 POWER WAVE 350 500 Codes 10104 10155 SVM109 A 65 00 RANGER 9 Codes 9975 9976 SVM110 A 45 00 SP250 Codes 9402 10002 SVM111 A 45 00 POWER WAVE 450 Codes 10105 10195 SVM112 A 65 00 WELDAN POWER 125 Codes 10158 10160 SVM113 A 45 00 LN25 Codes 9218 10150 SVM114 A 45 00 SP255 Codes 10164 10165 SVM115 A 45 00 Idealarc CV 300 Codes 9456 10181 SVM116 A 45 00 Wire matic 250 Codes 9799 10004 SVM117 A 45 00 Square Wave TIG 355 Codes 9951 9955 SVM118 A 45 00 Wire matic 255 Codes 10166 10167 SVM119 A 45 00 Ranger 10 LX Codes 9975 9976 SVM120 A 45 00 TOTAL SHIP MANUALS TO Name Address Phone SD 267 3 96 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using
22. atter or metal 23 FUMES AND GASES 4 can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and 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 products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 a
23. d MIG PULSER CONTROLS AND SETTINGS The MIG Pulser has three adjustments consisting of two switches Peak Current and Background Current and one knob Arc Length See figure B 1 7 LOW MED HIGH NORMAL HIGH PEAK AMPS BACKGROUND AMPS 7 N N ARC LENGTH Figure 1 MIG PULSER Controls OPERATION GUIDELINES The suggested steps for initially establishing a welding procedure are as follows 1 Set the Peak Current to Low Background Current to Normal and Arc Length to minimum 2 Set the desired wire feed speed on the feeder 3 Pull the gun trigger to establish an arc Increase the Arc Length setting until a stable arc is present If the arc will not start with the Arc Length set to min imum raise the Arc Length until a good start occurs 4 Once a stable arc is established the Peak Current level can be increased resulting in a broader soft er arc This might be useful for out of position work or for low travel speeds Conversely for faster trav el speeds lower Peak Current settings are recom mended 5 The Background Current affects the overall heat input to the weld It also can affect arc stability Too low of a Background Current can lead to a pop ping arc Adjusting the Peak Current Background Current or Arc Length will lead to changes that can be both seen and heard in the arc It is best to exper
24. d on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c 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 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier 6 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 levage 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
25. de the work cable should also be on your right side AN N 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 B SAFETY n ELECTRIC SHOCK can kill 3 8 The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode
26. g 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 circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c LINCOLN amp Ea CYLINDER may explode m 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 Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder
27. il or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders CHECKONE Address Please Invoice only if order is over 50 00 I Check or Money Order Enclosed U S Funds only Credit Card gt Telephone Signature as it appears on Charge Card er No LILI ee ate LL Ly USE THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 looks OR FREE INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 li incon Welding School Titles Price Code Quantity Cost ED 80 New Lessons in Arc Welding 5 00 L J formation Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings H Lec wies ene a Incentive Management IM A New Approach to Industrial Economics 5 00 Educational Video Information ED 93 Lames F Lincoln Arc Welding Foundation Book Information JFLF 515 Welding Preheat Calculator 500 WC8 Pipe Welding Charts 450 Em I SUB TOTAL pA etna Shipping Costs tam TE WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese
28. iment with var ious settings to familiarize yourself with their effects If the wire feed speed is changed at the wire feeder it is typical to need to raise the Arc length setting also If the wire feed speed is increased a great deal it may be necessary to increase the Peak Current setting as well Changes in wire size require similar procedural changes Larger wire sizes require higher Arc Length settings and possibly higher Peak Currents Note that a sound weld with good operator appeal can be achieved with more than one combination of set tings For instance raising the Peak Current one posi tion typically raises the arc length causing a definite change in the sound of the weld The MIG Pulser is based on adaptive principles n an adaptive pulser many variables can affect the arc length Stick out gun position weld position gas mix ture electrode composition electrode surface condi tion the switch settings and the Arc Length control All of these conditions feed back into the circuitry allowing the MIG Pulser to adapt the arc length to the welding conditions MIG PULSER LINCOLN B4 OPERATION B 4 PULSE WELDING PROCEDURE type of information These variables include but are GUIDELINES not limited to welding procedure plate chemistry and temperature weldment design fabrication methods and service requirements Tables B 2 and B 3 list initial settings guidelines for pulse welding with the MIG PUL
29. mps at 60 The single phase rating of the V300 PRO must be reduced from 250 amps 60 to 200 amps 60 when pulsing The single phase rating of the V300 I must be reduced from 200 amps 60 to 150 amps 60 when pulsing Refer to Table B 1 LIMITATIONS The V300 MIG Pulser combination cannot be used with long work and electrode leads The total length of the welding leads work lead length plus electrode lead length should not exceed 50 feet If longer cables are used refer to the Output Cables for Pulse Welding section in the Installation chapter for limita tions The Magnum Spoolgun MIG Pulser combination will not run low wire feed speed fine wire aluminum pro cedures well These wires are best run in a spray mode GMAW P offers few advantages in those areas The voltage meter on the wire feeder will not display voltage due to the lack of a 21 lead in the feeder con nection The V300 with a MIG Pulser may not be suitable for use neara high frequency arc starter such as is found in a TIG welding power source or a plasma cutter Refer to High Frequency Interference Protection section in the Installation section of this manual Problems with the trigger interlock may be experienced when using the MIG PULSER with an LN9 GMA that has a L7265 2 power board TABLE B 1 V300 OUTPUT DERATING V300 PRO Standard V300 PRO Rating Input Power without MIG Pulser 3 Phase 60 Hz 1 Phase 60 Hz V300 I Standard 300 Rating Input
30. 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 and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment 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 Mar 95 iv SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel 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
31. oubleshooting assistance before you proceed MIG PULSER LINCOLN D 2 TROUBLESHOOTING D 2 Observe all Safety Guidelines detailed througout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION PROBLEMS The MIG PULSER does not give a 1 Incorrect settings at the V300 satisfactory Weld Make sure the V300 switches are set in the proper positions See V300 SETTINGS in the Operation section of this manual Output Cables are either too long or of improper size See OUT PUT CABLES FOR PULSE WELDING in the Installation sec tion of this manual The control cable may be extend ed too long Do not use more than one optional 25 foot control cable extension There may be high frequency interference Refer to the HIGH FREQUENCY INTERFERENCE PROTECTION section in the Installation section of this manual Contact your Local Lincoln Authorized for proper installation guidelines Field Service Facility for technical troubleshooting assistance The voltmeter on the wire feeder if 1 This is normal The wire feeder equipped will not display voltmeter will not display since there is no 21 lead in the feeder connection 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 MIG PULSER
32. re available from your welding distributor or from the manufacturer Mar 95 SAFETY 7 WELDING SPARKS can 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 Recommended 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 cuttin
33. rom the top of the MIG Pulser as shown in figure A 1b MIG PULSER HIGH FREQUENCY INTERFERENCE PROTECTION A V300 with a MIG Pulser may not be suitable for use neara high frequency arc starter such as is found in a TIG welding power source or a plasma cutter The V300 should be located at least 15 feet 5 meters from the high frequency source There should be at least 25 feet 7 5 meters or greater separation between the ground connections and welding or cutting arcs of the V300 and the high frequency source ELECTRICAL INPUT CONNECTIONS MACHINE GROUNDING The MIG Pulser is grounded to the V300 by the ground lead carried inside the Control Cable Ground the V300 according to all local and national electrical codes Also refer to the V300 operators manual for any other grounding considerations SUPPLY CONNECTIONS The MIG Pulser receives its input power from the V300 through the Control Cable CONNECTION TO A V300 WARNING Turn the Power switch on the V300 OFF before con necting or disconnecting input power lines output cables or control cables CONTROL CABLE CONNECTION The MIG Pulser is supplied with a wye adapter for making connections to the V300 The 14 pin plug should be inserted into the V300 Wire Feeder recepta cle the 14 pin socket is for the wire feeder Control Cable and the 6 pin socket connects directly to the MIG Pulser Refer to figure A 2 If a DC TIG Starter is attached and connected to
34. sed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 students have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location 4d lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment by 4 th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 l 10 00 For order value between 50 00 amp 99 99 l 15 00 For order value between 100 00 amp 149 00 l For North America invoiced orders over 50 00 credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface ma
35. the coupon below The hardbound book contains over 750 pages of welding infor mation techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quan tity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and drafts men use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embos
36. ualified personnel should per form this installation Turn the input power OFF at the dis connect switch or fuse box before work ing on this equipment Do not touch electrically hot parts Always connect the V300 grounding terminal located on the bottom of the input connection box to a good electri cal earth ground Only qualified personnel should install use or service this equipment LOCATION The MIG Pulser can be used in the same locations and environments as the V300 It is rated for use in damp dirty environments MOUNTING BRACKETS Locate the two mounting brackets and rubber bumper with screw that are supplied with the MIG Pulser in the loose parts bag To prevent accidentally dropping the unit always secure the MIG Pulser to a stable surface with one of the brackets The first bracket is designed to hook onto the front handle of the V300 allowing the MIG Pulser to be located next to the V300 Control Panel Attach this bracket as shown in figure A 1a by using the two screws from the top of the MIG Pulser To prevent the MIG Pulser from scratching the paint off the V300 affix the rubber bumper to the bottom corner of the MIG Pulser case with the longer provided screw The second bracket is a universal bracket that is designed to allow the MIG Pulser to be fastened to any secure surface Attach the bracket to the desired sur face Then attach the MIG Pulser to the universal bracket using the two screws f
37. 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 10 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 du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 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 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 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 LINCOLN for selecting a QUALITY product by Lincoln Electric We want you hank You to take pride in operating this Lincoln Electric Company product s as much pride as we have in bringing this product to you Please Examine Carton
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