Lincoln Electric IM736-D manual

PO WER MIG ™ 300 OPERA TOR’S MANUAL IM736-D February, 2004 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 T[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

4 FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical[...]

iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page ________________________________________________________________________ Installation ................................................................................................................... ....Section A Technical Specifications ...............................................................................[...]

A-1 A-1 INST ALLA TION Input Voltage/ 230Amps @ 300Amps @ 75°C Copper Wire Fuse Frequency (Hz) 29 Volts 32 Volts AWG (IEC) or (100% Duty Cycle) (60% Duty Cycle) Sizes (MM 2 ) Breaker Size 208/60* 48 A 72 A 6 (16 mm 2 ) 90 A 230/60 43 A 62 A 6 (16 mm 2 ) 80 A 460/60 22 A 31 A 10 (6 mm 2 ) 50 A 575/60 17 A 25 A 12 (2.5 mm 2 ) 35 A NOTE: Use #10 AWG [...]

A-2 A-2 INST ALLA TION ONL Y QUALIFIED PERSONNEL SHOULD INST ALL, USE OR SERVICE THIS EQUIP- MENT . UNCRA TING 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 Bot[...]

A-3 A-3 INST ALLA TION FIGURE A.2 — Receptacle Diagram 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. 3. The POWER MIG is shipped with a [...]

A-4 GUN AND CABLE INST ALLA TION 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.. Turn the welder power switch off before installing gun[...]

A-5 A-5 INST ALLA TION 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 t[...]

B-1 B-1 OPERA TION 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 FCA[...]

B-2 B-2 OPERA TION POWER MIG 300 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-o[...]

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 selections are: • Weld Mode (Process selection choices) • Preflow / Postflow • Run-In • Sta[...]

B-4 B-4 OPERA TION POWER MIG 300 SETTING AND CONFIGURING THE POWER MIG 300 FOR WELDING • 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[...]

B-5 B-5 OPERA TION POWER MIG 300 MUL TI-PROCESS P ANEL 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 machi[...]

B-6 B-6 OPERA TION POWER MIG 300 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 ca[...]

B-7 B-7 OPERA TION POWER MIG 300 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 dist[...]

B-8 B-8 OPERA TION POWER MIG 300 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. Lowe[...]

B-9 B-9 OPERA TION POWER MIG 300 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 When triggered, the electrode and drive mecha- nism are electrically “ hot ” relative to work and ground and remain “ [...]

B-10 B-10 OPERA TION POWER MIG 300 SPECIAL WELDING PROCESSES A V AILABLE ON THE POWER MIG 300 PULSE WELDING (GMA W-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. Pul[...]

B-1 1 B-1 1 OPERA TION POWER MIG 300 PULSE-ON-PULSE ™ (GMA W-PP) Pulse on Pulse ™ is a Lincoln process specifically designed for use in welding relatively thin (less than 1/4" thick) aluminum (See Table B.3). It gives weld beads with very consistent uniform ripple. In Pulse on Pulse modes, two distinct pulse types are used, instead of the [...]

B-12 B-12 OPERA TION POWER MIG 300 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[...]

C-1 C-1 ACCESSORIES 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 * .035 Aluminum recommended for Push-Pull systems only. 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K2153-1) This kit helps push feeding aluminum through stan- d[...]

C-2 C-2 ACCESSORIES Non-Synergic Weld Modes (Mode 5) • 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. • The left Display (WFS / AMPS) on the POWER MIG 300 will have 4 dashes (----) to indicate that the left control knob on the power [...]

D-1 D-1 MAINTENANCE CONT ACT TIP AND GAS NOZZLE INST ALLA TION 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. ([...]

D-2 D-2 MAINTENANCE 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 against the Liner. This screw should only be gently tightened. Over[...]

E-1 E-1 TROUBLESHOOTING 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. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine[...]

E-2 TROUBLESHOOTING E-2 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. CAUTION Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POS[...]

POWER MIG 300 E-3 E-3 TROUBLESHOOTING 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 str[...]

POWER MIG 300 E-4 E-4 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. 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. CAUTION PROBLEMS (SYMPTOMS) [...]

POWER MIG 300 E-5 E-5 TROUBLESHOOTING PROBLEMS (SYMPTOMS) Gas does not flow when gun trigger is pulled. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure gas supply is con- nected properly and turned “ on ” . 2. If the gas solenoid does actuate (click) when the gun trigger is pulled there may be a restriction in the gas supply line. 3. The gun ca[...]

E-6 TROUBLESHOOTING E-6 POWER MIG 300 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION Fault Cod[...]

E-7 TROUBLESHOOTING E-7 POWER MIG 300 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS [...]

E-8 TROUBLESHOOTING E-8 POWER MIG 300 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS [...]

E-9 TROUBLESHOOTING E-9 POWER MIG 300 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS [...]

E-10 TROUBLESHOOTING E-10 POWER MIG 300 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PUSH PU[...]

POWER MIG 300 F-1 F-1 WIRING DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment cod[...]

F-2 F-2 WIRING DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.. ALL[...]

F-3 F-3 WIRING DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.. WIR[...]

F-4 F-4 WIRING DIAGRAM POWER MIG 300 WIRI NG DIAGRAM POWER MIG 30 0 (FOR CODES 11097, 11098) J4 1 2 3 4 5 6 7 8 9 10 11 12 J3 1 2 3 4 5 6 7 8 9 10 J7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 J 9 1 2 3 4 5 6 J8 1 2 3 4 5 6 7 8 J2 1 2 3 4 J 1 0 B 1 2 J 1 1 1 2 3 4 1 2 J6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 J5 1 2 3 4 J1 1 2 3 4 5 6 7 8 9 10 11 12 13[...]

DIMENSION PRINT F-5 POWER MIG 300 F-5 3-00F M19231[...]

NOTES POWER MIG 300[...]

NOTES POWER MIG 300[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA E[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

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