Lincoln Electric POWER MIG SVM160-B manual

PO WER MIG ™ 300 SER VICE MANUAL 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 PR[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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. U[...]

POWER MIG 300 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 manufacture[...]

POWER MIG 300 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv 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: [...]

6 6 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety .................................................................................................................................................i-iv Installation ............................................................................................................................. Se[...]

A-1 A-1 T ABLE OF CONTENTS - INST ALLA TION SECTION - INSTALLATION ...................................................................................................................... Section A Technical Specifications ....................................................................................................... ......A-2 Safety Precauti[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 A-2 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 ) Br[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-3 A-3 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 ba[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-4 A-4 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 A[...]

A-5 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[...]

POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-6 A-6 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[...]

POWER MIG 300 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-1 B-1 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Definitions of Welding Modes .........................[...]

POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 B-2 OPERA TION COMMON WELDING ABBREVIA- TIONS WFS • Wire Feed Speed CC • Constant Current CV • Constant Voltage GMAW (MIG) • Gas Metal Arc welding GMAW-[...]

POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-3 B-3 OPERA TION 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[...]

POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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?[...]

POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-5 B-5 OPERA TION SETTING AND CONFIGURING THE POWER MIG 300 FOR WELDING • Check that the electrode polarity is correct for the process and turn the Power Switch [...]

POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-6 B-6 OPERA TION 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[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-7 B-7 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 preferenc[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-8 B-8 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 [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-9 B-9 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 i[...]

POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-10 B-10 OPERA TION 4. Re-install the Retaining Collar. Make sure that the Release Bar “pops up” and that the collar retainers fully engage the retaining ring [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-1 1 B-1 1 OPERA TION POWER MIG 300 SPECIAL WELDING PROCESSES AV AILABLE ON THE POWER MIG 300 PULSE WELDING (GMA W-P) The pulsed-arc process is, by definition, a spray trans- fe[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-12 B-12 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&quo[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-13 B-13 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[...]

B-14 NOTES POWER MIG 300 B-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

POWER MIG 300 C-1 C-1 T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Drive Roll Kits .............................................................................................................................C-2 Pu[...]

POWER MIG 300 C-2 C-2 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 t[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C-3 C-3 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 dis[...]

C-4 C-4 NOTES POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

POWER MIG 300 D-1 D-1 T ABLE OF CONTENTS -MAINTENANCE- Maintenance .......................................................................................................................... Section D Safety Precautions & General Maintenance ...............................................................................D-2 Liner Removal and Repl[...]

POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-2 D-2 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 [...]

D-3 D-3 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 ti[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 POWER MIG 300 Theory of Operation ............................................................................................................ .Section E General Description ....................................................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GENERAL 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 60% [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT VOL T AGE AND MAIN TRANS- FORMER Single-phase input power is brought into the rear of the Power MIG 300 through a three-prong plug and input cable. A reconnect panel, also [...]

THEOR Y OF OPERA TION E-4 E-4 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT RECTIFIER, CHOPPER ASSEMBL Y AND FEEDBACK The 60 V AC output from the main transformer sec- ondary is connected to an input rect[...]

DIODE CONTROL RECTIFIER AND POWER BOARD The Power Board receives approximately 40 VDC from the Diode Control Rectifier . In turn, the Power Board supplies a variety of regulated DC voltages to the Weld Control Board, which it uses to power its many circuits and communication functions. The Power Board also supplies +20 VDC to the Chopper Assembly .[...]

WELD CONTROL BOARD The Weld Control Board performs the primary interfac- ing functions to establish and maintain output control of the Power MIG 300 machine. The function generator and weld files reside within the Weld Control Board hardware and software. Digital command signals and feedback information from other machine components are received an[...]

E-7 E-7 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRE DRIVE MOT OR AND FEED- BACK The Wire Drive Motor is controlled by the Feeder Board and the Weld Control Board. A motor speed feedback signal is generat[...]

THERMAL PROTECTION T wo normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are con- nected to the Weld Control board. One of the ther- mostats is located on the Chopper Assembly board, and one is on the secondary of the Main T ransformer . Excessive temperatures may [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-9 E-9 POWER MIG 300 FIGURE E.8 – IGBT OPERA TION DRAIN SOURCE GATE INJECTING LAYER BUFFER LAYER DRAIN DRIFT REGION BODY REGION p + n + n - p n + n + DRA[...]

PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the pulse width is known as MODULA TION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine[...]

CHOPPER TECHNOLOGY FUNDAMENT ALS The new era of welding machines such as the Power MIG 300 employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc. Hence the name “Chopper .” The biggest advantage of chopper technology is the high-speed control of the arc, simi[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 POWER MIG 300 T roubleshooting & Repair Section ................................................................................ Section F How to Use T roubleshooting Guide .................................................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW T O USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may[...]

POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical co[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 POWER MIG 300 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lin[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 POWER MIG 300 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not underst[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 POWER MIG 300 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lin[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 POWER MIG 300 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do not underst[...]

F-8 F-8 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lin[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 POWER MIG 300 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the Lin[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 POWER MIG 300 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the L[...]

F-11 F-11 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely , contact the L[...]

CHOPPER BOARD CAP ACIT OR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe[...]

TROUBLESHOOTING & REP AIR F-13 F-13 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CHOPPER BOARD CAP ACIT OR DISCHARGE PROCEDURE (continued) FIGURE F .1 – CHOPPER BOARD CAP ACITOR TERMINAL DISCHARGE PROCED[...]

MAIN TRANSFORMER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and pr[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-15 F-15 POWER MIG 300 MAIN TRANSFORMER TEST (continued) FIGURE F .2 – MAIN TRANSFORMER TEST POINT LOCA TIONS PROCEDURE The ON/OFF POWER SWITCH w[...]

CHOPPER BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and preca[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 POWER MIG 300 CHOPPER BOARD TEST (continued) FIGURE F .3 – CHOPPER BOARD CONNECTIONS T ABLE F .1– CHOPPER BOARD RESIST ANCE TEST T ABL[...]

TROUBLESHOOTING & REP AIR F-18 F-18 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CHOPPER BOARD TEST (continued) FIGURE F .4 L1 1088-1 J6 PWM SIGNAL TEST 1. Locate 607 (7J6) and 615 (15J6) on the control bo[...]

CONTROL RECTIFIER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes and[...]

TROUBLESHOOTING & REP AIR F-20 F-20 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL RECTIFIER TEST (continued) FIGURE F .5 FIGURE F .6 - + CONTROL RECT IF IER + 6800/75 X6 X5 X4 X3 30 VA C 115 V AC FA[...]

OUTPUT RECTIFIER ASSEMBL Y TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety no[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 POWER MIG 300 OUTPUT RECTIFIER ASSEMBL Y TEST (continued) FIGURE F .7– OUTPUT RECTIFIER ASSEMBL Y LOCA TION TEST PROCEDURE 1. Disconnect[...]

WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please obser[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 POWER MIG 300 WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST (continued) FIGURE F . 8 – PLUG J83 AND J84 LOCA TIONS ON FEEDER BOARD TES[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 POWER MIG 300 WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST (continued) TEST FOR SUPPL Y VOL T AGE TO T ACHOMETER AND FEEDBACK VOL T AGE[...]

ENCODER PC BOARD TEST (FOR CODES ABOVE 10562) Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please obser[...]

F-27 F-27 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR ENCODER PC BOARD TEST (continued) G3884 J82 3243 J85 858 857 855 851 1 8510 859 FIGURE F . 9 - FEEDHEAD P .C. BOARD TEST PRO[...]

TROUBLESHOOTING & REP AIR F-28 F-28 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENCODER PC BOARD TEST (continued) FROM LEAD TO LEAD EXPECTED VOL T AGE 855 3243 15 VDC 5J85 3J82 851 1 3243 0 OR 15 VDC 1 1J[...]

CURRENT TRANSDUCER TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes an[...]

TROUBLESHOOTING & REP AIR F-30 F-30 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT TRANSDUCER TEST (continued) FIGURE F .10 L1 1088-1 J8 804 802 801 806 TEST PROCEDURE 1. Remove input power to the ma[...]

TROUBLESHOOTING & REP AIR F-31 F-31 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CURRENT TRANSDUCER TEST (continued) T ABLE F .2 – CURRENT TRANSDUCER FEEDBACK VOL T AGE OUTPUT LOAD CURRENT 500 450 400 35[...]

POWER MIG 300 SCROLLING DASHES TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all saf[...]

TROUBLESHOOTING & REP AIR F-33 F-33 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 300 SCROLLING DASHES TEST (continued) TEST PROCEDURES: For Machines with code 10952, 10958 and 1 1000. 1. Hold “[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-34 F-34 POWER MIG 300 This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division r[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 POWER MIG 300 SCOPE SETTINGS V olts/Div .....................20V/Div . Horizontal Sweep .....5 ms/Div . Coupling .........................[...]

MOT OR & GEAR BOX ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, ple[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-37 F-37 POWER MIG 300 MOT OR & GEAR BOX ASSEMBL Y REMOV AL AND REPLACEMENT (continued) REMOV AL PROCEDURE ELECTRIC SHOCK can kill . High volta[...]

TROUBLESHOOTING & REP AIR F-38 F-38 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MOT OR & GEAR BOX ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .1 1 FOR CODES BELOW 10952 13 7 11 6 10 12 9 8[...]

TROUBLESHOOTING & REP AIR F-39 F-39 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MOT OR & GEAR BOX ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .12 FOR CODES ABOVE 10958 15 14 9 10 13 12 11 [...]

OUTPUT RECTIFIER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe a[...]

TROUBLESHOOTING & REP AIR F-41 F-41 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) ELECTRIC SHOCK can kill . High voltage is present when input power is [...]

TROUBLESHOOTING & REP AIR F-42 F-42 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFIER REMOV AL AND REPLACEMENT (continued) 9. Using a 3/8 in. wrench, remove the 4 nuts and lock washers holding [...]

CHOPPER BOARD ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please ob[...]

TROUBLESHOOTING & REP AIR F-44 F-44 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CHOPPER BOARD ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .14 – CHOPPER BOARD ASSEMBL Y DET AILS REMOV AL PROC[...]

TROUBLESHOOTING & REP AIR F-45 F-45 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CHOPPER BOARD ASSEMBL Y REMOV AL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Attach the chopper assembly brackets t[...]

TROUBLESHOOTING & REP AIR F-46 F-46 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric f[...]

REMOV AL PROCEDURE ELECTRIC SHOCK can kill . High voltage is present when input power is applied to the machine. NOTE: Cut cable ties as needed to improve access. PREP ARA TION 1. Disconnect main input power from the machine. 2. Remove the case side panels using a 3/8 in. nut- driver . 3. Perform the Chopper Board Capacitor Discharge Procedure . 4.[...]

TROUBLESHOOTING & REP AIR F-48 F-48 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE REMOV AL AND REPLACEMENT (continued) LEAD DISCONNECTION 8. Using a phillips head screwdriv[...]

TROUBLESHOOTING & REP AIR F-49 F-49 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN TRANSFORMER AND OUTPUT CHOKE REMOV AL AND REPLACEMENT (continued) FIGURE F .15 BACK SIDE 5 12 11 8 7A 7C TEN (10) 7B BA[...]

TROUBLESHOOTING & REP AIR F-50 F-50 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F AN MOTOR ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory traine[...]

TROUBLESHOOTING & REP AIR F-51 F-51 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F AN MOTOR ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .16 – F AN MOTOR ASSEMBL Y REMOV AL 6 4B 4A 6 5 REMOV A[...]

VOL T AGE & CURRENT CALIBRA TION PROCEDURE Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please obse[...]

TROUBLESHOOTING & REP AIR F-53 F-53 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC VOL T AGE & CURRENT CALIBRA TION PROCEDURE (continued) CALIBRA TION CHECK (CODE 10562) The calibration of the Power Mig [...]

TROUBLESHOOTING & REP AIR F-54 F-54 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC VOL T AGE & CURRENT CALIBRA TION PROCEDURE (continued) 9. W ait for the machine’ s output to be automati- cally turned[...]

TROUBLESHOOTING & REP AIR F-55 F-55 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC VOL T AGE & CURRENT CALIBRA TION PROCEDURE (continued) CALIBRA TION CHECK (CODES 10952 AND UP) The calibration of the Po[...]

TROUBLESHOOTING & REP AIR F-56 F-56 POWER MIG 300 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC VOL T AGE & CURRENT CALIBRA TION PROCEDURE (continued) 9. W ait for the machine’ s output to be automati- cally turned[...]

RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. OR • If you repair or replace any electrical components. TEST MODE 5 INPUT IDLE W A TTS AND AMPS Input V olts/Hertz Maximum Idle W atts Maximum Idle Amps 230/60 [...]

G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM (CODE 10562 ONL Y -G3852). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 WIRING DI[...]

ELECTRICAL DIAGRAMS G-2 POWER MIG 300 WIRING DIAGRAM - POWER MIG 300 CODE 10562 ONL Y ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR. PA NE L RECEPTACL E CAVITY NU MBERING SEQU ENCE (V IEW ED FROM LEAD SIDE O F RECEPTACL E) 9 PIN J50 1 2 3 654 987 3 2 1 456 789 9 PIN P50 LEAD COLOR CODE: B=BLACK OR GRAY R= RED OR PINK W=WHITE G=GREEN (W/YELLOW ST[...]

ELECTRICAL DIAGRAMS G-3 POWER MIG 300 WIRING DIAGRAM - POWER MIG 300 CODE 10952 ONL Y ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR. PA NE L RECEPTACL E CAVITY NU MBERING SEQU ENCE (V IEW ED FRO M LEAD SID E OF RECE PTACLE) 9 PIN J50 1 2 3 654 987 3 2 1 456 789 9 PIN P50 LEAD COLOR COD E : B= B LA CK OR GR AY R= RED O R PIN K W=WHI TE G= GR EEN [...]

ELECTRICAL DIAGRAMS G-4 POWER MIG 300 WIRING DIAGRAM - POWER MIG 300 CODE 10958 AND 1 1000 ONL Y ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR. PA NE L RECEPTACL E CAVITY NU MBERING SEQU ENCE (V IEW ED FROM LEAD SIDE O F RECEPTACL E) 9 PIN J50 1 2 3 654 987 3 2 1 456 789 9 PIN P50 LEAD COLOR COD E : B= B LA CK OR GR A Y R= RED O R PIN K W=WHI TE[...]

ELECTRICAL DIAGRAMS G-5 POWER MIG 300 WIRING DIAGRAM - POWER MIG 300 CODE 1 1097 AND 1 1098 ONL Y 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 [...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-6 POWER MIG 300 SCHEMA TIC - COMPLETE MACHINE - CODE 10958 AND 1 1000 ONL Y EN -17 0 S O L I D E D G E G4315 ENGINEERING CONTROLLED MANUFACTURER: No CHA[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-7 POWER MIG 300 SCHEMA TIC - COMPLETE MACHINE - CODE 1 1097 AND 1 1098 ONL Y EN -17 0 S O L I D E D G E G4512 ENGINEERING CONTROLLED MANUFACTURER: No CH[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-8 POWER MIG 300 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #1 - CODE 10562 - 1 1098 G-8 NOTE: This diagram is for reference only . It may not be accurate fo[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-9 POWER MIG 300 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #2 - CODE 10562 - 1 1098 G-9 NOTE: This diagram is for reference only . It may not be accurate fo[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-10 POWER MIG 300 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #3 - CODE 10562 - 1 1098 G-10 NOTE: This diagram is for reference only . It may not be accurate [...]

ELECTRICAL DIAGRAMS G-11 POWER MIG 300 SCHEMA TIC - DIGIT AL CONTROL PC BOARD #4 - CODE 10562 - 1 1098 G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Re[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-12 POWER MIG 300 SCHEMA TIC - POWER SUPPL Y PRINTED CIRCUIT BOARD - CODE 10562 - 1 1098 .1 C53 Vfb2 Vref 1 100K R29 CNY17-3 OCI2 42 1 6 5 .5W 27V DZ2 VF[...]

ELECTRICAL DIAGRAMS G-13 POWER MIG 300 SCHEMA TIC - CHOPPER BOARD - CODE 10562 - 1 1098 G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master [...]

ELECTRICAL DIAGRAMS G-14 POWER MIG 300 SCHEMA TIC - MSP3 PC BOARD - CODE 10562 - 1 1098 G-14 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master [...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-16 POWER MIG 300 SCHEMA TIC - FEEDER PC BOARD BOARD - CODE 10562 - 1 1098 - SHEET 1 G-16 NOTE: This diagram is for reference only . It may not be accura[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-17 POWER MIG 300 SCHEMA TIC - FEEDER PC BOARD BOARD - CODE 10562 - 1 1098 - SHEET 2 G-17 NOTE: This diagram is for reference only . It may not be accura[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-18 POWER MIG 300 SCHEMA TIC - SPOOL GUN PC BOARD - CODE 10562 - 11098 - SHEET 1 G-18 NOTE: This diagram is for reference only . It may not be accurate f[...]

Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-19 POWER MIG 300 SCHEMA TIC - SPOOL GUN PC BOARD - CODE 10562 - 11098 - SHEET 2 G-19 NOTE: This diagram is for reference only . It may not be accurate f[...]

ELECTRICAL DIAGRAMS G-20 POWER MIG 300 SCHEMA TIC - ENCODER PC BOARD - CODE 10562 ONL Y G-20 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Master [...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

ELECTRICAL DIAGRAMS G-22 POWER MIG 300 SCHEMA TIC - DISPLA Y PC BOARD - CODE 10562 - 1 1098 G-22 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Retur n to Section TOC Retur n to Section TOC Return to Master TOC Retur n to Master TOC Return to Mas[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information wi[...]

PO WER MIG 300 SVM160-B[...]