Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
4 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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 contr...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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...
Page 7 - TABLE OF CONTENTS; Page
vi vi TABLE OF CONTENTS Page ________________________________________________________________________ Installation.......................................................................................................................Section A Technical Specifications ...................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – POWER MIG 300
A-1 A-1 INSTALLATION 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 1...
Page 9 - UNCRATING THE POWER MIG 300; Before starting the installation, check with the local; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
A-2 A-2 INSTALLATION ONLY QUALIFIED PERSONNEL SHOULDINSTALL, USE OR SERVICE THIS EQUIP-MENT. UNCRATING THE POWER MIG 300 Cut banding and lift off cardboard carton. Cut bandingholding the machine to the skid. Remove foam andcorrugated packing material. Untape accessories fromGas Bottle Platform. Unsc...
Page 10 - FIGURE A.2 — Receptacle Diagram
A-3 A-3 INSTALLATION FIGURE A.2 — Receptacle Diagram CONNECT TO A SYSTEMGROUNDING WIRE. SEETHE UNITED STATESNATIONAL ELECTRICALCODE AND/OR LOCALCODES FOR OTHERDETAILS AND MEANS FORPROPER GROUNDING. CONNECT TO HOT WIRESOF A THREE-WIRE, SINGLEPHASE SYSTEM OR TO ONEPHASE OF A TWO ORTHREE PHASE SYSTEM. ...
Page 11 - SHIELDING GAS; CAUTION
A-4 GUN AND CABLE INSTALLATION A M a g n u m 3 0 0 g u n a n d 1 5 F t . ( 4 . 6 m ) c a b l e(12Ft.(3.7m) for Codes 11000 and below) are provid-ed with the POWER MIG 300. A Magnum cable linerfor .035-.045" (0.9-1.2 mm) electrode and contact tipsfor .035” (0.9mm) and .045” (1.2mm) are included f...
Page 13 - OPERATION; DEFINITIONS OF WELDING MODES
B-1 B-1 OPERATION C O M M O N W E L D I N G A B B R E V I A -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 we...
Page 14 - PRODUCT DESCRIPTION; Other features; CONTROLS AND SETTINGS
B-2 B-2 OPERATION POWER MIG 300 PRODUCT DESCRIPTION The POWER MIG 300 is a complete semiautomaticmulti-process DC arc welding machine offering CVand CC DC welding. It is rated for 300 amps, 32 voltsa t a 6 0 % d u t y c y c l e . T h e s t a n d a r d m a c h i n e i sequipped to weld CC-Stick, CC-G...
Page 15 - OPERATIONS; CV Processes
5. MULTI-PROCESS PANEL - This panel enables selection of weld modes as well as adjustment of certain weldparameters within each weld mode. The eight discrete LED ’ s are used to identify which selec- tion will be shown on the display. The possible selectionsare: • Weld Mode (Process selection choice...
Page 16 - SETTING AND CONFIGURING THE POWER
B-4 B-4 OPERATION 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 POWERMIG 300 will default to ...
Page 17 - MULTI-PROCESS PANEL FUNCTIONS; Weld Mode
B-5 B-5 OPERATION POWER MIG 300 MULTI-PROCESS PANEL FUNCTIONS Weld Mode Setting the Weld Mode is selecting the proper programfrom the ones available in the machine ’ s memory for a particular welding application. The table on the right sideof the front panel (See Figure B.2) gives information ont h ...
Page 18 - Arc Control
B-6 B-6 OPERATION POWER MIG 300 Arc Control (See Table B.2) There are no specific unit values offered because the settingof this feature largely depends upon operator preference.Arc Control has a different effect on the character of the arcdepending upon the welding process applied. In SMAW (STICK m...
Page 19 - WIRE DRIVE ROLL
B-7 B-7 OPERATION 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 increasedfrom +1 to +10 the frequency of the Pulse on Pulse arrayincreases. As the frequency incr...
Page 21 - FEEDING WIRE ELECTRODE; hot; IDLE ROLL PRESSURE SETTING
B-9 B-9 OPERATION 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 ” rela...
Page 22 - pulse; PEAK AMPS
B-10 B-10 OPERATION POWER MIG 300 S P E C I A L W E L D I N G P R O C E S S E SAVAILABLE ON THE POWER MIG 300 PULSE WELDING (GMAW-P) The pulsed-arc process is, by definition, a spray trans-fer process wherein spray transfer occurs in pulses atregularly spaced intervals. In the time between pulses,th...
Page 23 - Pulse on Pulse
B-11 B-11 OPERATION POWER MIG 300 PULSE-ON-PULSE ™ (GMAW-PP) Pulse on Pulse ™ is a Lincoln process specifically designed for use in welding relatively thin (less than1/4" thick) aluminum (See Table B.3). It gives weldbeads with very consistent uniform ripple. In Pulse on Pulse modes, two distinc...
Page 24 - POWER MODE; Recommended Welding Procedures for Power Mode - Table B.4
B-12 B-12 OPERATION POWER MIG 300 POWER MODE ™ T h e P o w e r M o d e ™ p r o c e s s w a s d e v e l o p e d b y Lincoln to maintain a stable and smooth arc at lowprocedure settings which are needed to weld thinm e t a l w i t h o u t p o p - o u t s o r b u r n i n g - t h r o u g h . F o rAlumin...
Page 25 - ACCESSORIES; DRIVE ROLL KITS; HOT
C-1 C-1 ACCESSORIES DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that areavailable 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...
Page 26 - POWER
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 willadjust the voltage that is displayed in the meterdirectly above it. • The left Display (WFS / AMPS) on the POWER MIG 300 will have 4 dashes (----) to indic...
Page 27 - MAINTENANCE; GUN TUBES AND NOZZLES; Have an electrician install and; GENERAL MAINTENANCE
D-1 D-1 MAINTENANCE CONTACT TIP AND GAS NOZZLEINSTALLATION a. Choose the correct size contact tip for the elec- trode being used (wire size is stenciled on the sideof the contact tip) and screw it snugly into the gasdiffuser. b. Be sure the nozzle insulator is fully screwed onto the gun tube and doe...
Page 28 - LINER REMOVAL AND REPLACEMENT
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. L a y t h e c a b l e s t r a i g h t a n d t r i m L i n e r t o 9 / 1 6 ” . Remove burrs. 7. Secure the gas diffuser into the tube. 8. Tighten the set...
Page 29 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; Step 3. RECOMMENDED COURSE OF ACTION
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 provi...
Page 30 - PROBLEMS
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 detai...
Page 31 - OUTPUT PROBLEMS
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 demonstrat...
Page 32 - FEEDING PROBLEMS
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 assistanc...
Page 33 - GAS FLOW PROBLEMS
POWER MIG 300 E-5 E-5 TROUBLESHOOTING PROBLEMS(SYMPTOMS) Gas does not flow when gun triggeris pulled. POSSIBLE AREAS OFMISADJUSTMENT(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 ispulled there may be a restric...
Page 35 - PUSH PULL WIRE FEEDING PROBLEMS
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 troubleshootin...
Page 38 - STALL FACTOR
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 troubleshoot...
Page 39 - WIRING DIAGRAMS; IRI
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 diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service D...
Page 41 - WIRING DIA
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 diag ram 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 ...
Page 42 - WIRING DIAGRAM
F-4 F-4 WIRING DIAGRAM POWER MIG 300 W IRI NG DI AGRAM POW ER MI G 3 00 (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 J9 1 2 3 4 5 6 J8 1 2 3 4 5 6 7 8 J2 1234 J10 B 1 2 J11 1 2 3 4 1 2 J6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...
Page 43 - DIMENSION PRINT
Page 44 - NOTES
Page 46 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...
