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IM736-D
February, 2004
™
POWER MIG 300
For use with machine Code Numbers: 10562, 10952, 10958, 11000, 11097, 11098
For use with machine
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importa
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All h
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque d’incendie dû aux étincelles
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi vi TABLE OF CONTENTS Page ________________________________________________________________________ Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ..........................................................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – POWER MIG 300 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current @ 230Amp Rated Output Input Current @ 300 Amp Rated Output 208/230/460/575/60 Hz 48/43/22/17 Amps 72/62/31/25 Amps RATED OUTPUT Input Voltage Duty Cycle Amps Volts at Rated Amperes 208 40% 300 Amps 32 Volts 230/460/575 60% 300 Amps 32 Volts 208/230/460/575 100% 230Amps 29 Volts OUTPUT Welding Current Range (Continuous) Maximum Open Circuit Voltage Welding Voltage Rang
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A-2 A-2 INSTALLATION ONLY QUALIFIED PERSONNEL SHOULD Read entire installation section before starting installation. INSTALL, USE OR SERVICE THIS EQUIP- MENT. SAFETY PRECAUTIONS UNCRATING THE POWER MIG 300 WARNING Cut banding and lift off cardboard carton. Cut banding ELECTRIC SHOCK can kill. holding the machine to the skid. Remove foam and � Do not touch electrically live corrugated packing material. Untape accessories from parts or electrode with skin or Gas Bottle Platform. Unscrew the two woo
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A-3 A-3 INSTALLATION FIGURE A.1 — Triple Voltage Machine Input Connections 3. The POWER MIG is shipped with a 10ft.(3.05m) input cable and plug connected to the welder. FIGURE A.2 — Receptacle Diagram Using the instructions in Figure A.2, have a quali- CONNECT TO A SYSTEM fied electrician connect the receptacle or cable to GROUNDING WIRE. SEE the input power lines and the system ground per THE UNITED STATES the U.S. National Electrical Code and any applica- NATIONAL ELECTRICAL CODE AND/OR LOCAL
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A-4 A-4 INSTALLATION GUN & CABLE ASSEMBLY INSTALLED GUN AND CABLE INSTALLATION INTO THE POWER MIG A Magnum 300 gun and 15Ft.(4.6m) cable 1. Unscrew knurled screw on the drive unit front end (12Ft.(3.7m) for Codes 11000 and below) are provid- (inside wire feed compartment) until tip of screw no ed with the POWER MIG 300. A Magnum cable liner longer protrudes into gun opening as seen from for .035-.045" (0.9-1.2 mm) electrode and contact tips front of machine. for .035” (0.9mm) and .045” (1.2mm) a
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A-5 A-5 INSTALLATION DO NOT ATTACH THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Inform your gas supplier of this condition. Oil or grease in the presence of high pressure oxygen is explosive. 3. Stand to one side away from the outlet and open the cylinder valve for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet. WARNING Be sure to keep your face away from the valve outlet when “cracking” the valve. 4. Attach the flow regulator to the cylinder va
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B-1 B-1 OPERATION Read entire Operation section before COMMON WELDING ABBREVIA- operating the POWER MIG 300. TIONS WARNING WFS ELECTRIC SHOCK can kill. � Wire Feed Speed � Do not touch electrically live parts or electrode with skin or CC wet clothing. Insulate yourself � Constant Current from work and ground. CV � Always wear dry insulating � Constant Voltage gloves. GMAW (MIG) FUMES AND GASES can be � Gas Metal Arc welding dangerous. � Keep your head out of fumes. GMAW-P (MIG) � Gas Metal Arc w
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B-2 B-2 OPERATION Other features PRODUCT DESCRIPTION Optional kits are available for push-pull welding, spool gun operation, push feeding of 3/64 aluminum with the The POWER MIG 300 is a complete semiautomatic standard POWER MIG 300 gun and wire feeder. A multi-process DC arc welding machine offering CV Dual Cylinder Mounting Kit is also offered. and CC DC welding. It is rated for 300 amps, 32 volts at a 60% duty cycle. The standard machine is CONTROLS AND SETTINGS equipped to weld CC-Stick, CC-
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B-3 B-3 OPERATIONS 5. MULTI-PROCESS PANEL - This panel enables selection 2. VOLT / TRIM METER - This meter displays either of weld modes as well as adjustment of certain weld the voltage or trim value depending on the status of parameters within each weld mode. the machine. Located below the display is the text "Volts" and "Trim." An LED light is illuminated to The eight discrete LED’s are used to identify which selec- the left of one of these in order to indicate the units tion will be shown o
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B-4 B-4 OPERATION 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 when the machine was powered down. The Multi- Process Panel defaults with the "Weld Mode" active. � Toggle the SET switch to the desired "Weld Mode" opera- tion. The Multi-Process Meter
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B-5 B-5 OPERATION Run-In MULTI-PROCESS PANEL FUNCTIONS � The Run-In function offers the ability to set a wire feed speed, from trigger until an arc is established, that is inde- Weld Mode pendent of the Welding or Start wire feed speed. Setting a Setting the Weld Mode is selecting the proper program Run-In WFS lower than the welding WFS avoids stubbing from the ones available in the machine’s memory for a problems when starting the arc. particular welding application. The table on the right side
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B-6 B-6 OPERATION Carbon steel electrodes employed in GMAW-S usually per- Arc Control (See Table B.2) form best when the droplet size is regulated by pinch to There are no specific unit values offered because the setting reduce the droplet size transferred with each short-circuit of this feature largely depends upon operator preference. event. Arc Control has a different effect on the character of the arc depending upon the welding process applied. When welding with solid stainless steel types o
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B-7 B-7 OPERATION In the case of special waveforms designed for pulsed weld- � In the GMAW, FCAW, and Power weld modes, crater ing aluminum, Pulse on Pulse™, the effect is similar to what WFS and voltage are adjustable using the control knobs occurs with standard pulse. As the Arc Control is increased on the upper case front. This in indicated by the flashing from +1 to +10 the frequency of the Pulse on Pulse array LED’s next to "WFS" and "VOLTS." increases. As the frequency increases the wel
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OPERATION B-8 B-8 5. Rotate the spindle and adapter so the retaining PROCEDURE FOR CHANGING spring is at the 12 o'clock position. DRIVE AND IDLE ROLL SETS 6. Position the Readi-Reel so that it will rotate in a direc- 1. Turn off the power source. tion when feeding so as to be de-reeled from top the 2. Release the pressure on the idle roll by swinging of the coil. the adjustable pressure arm down toward the back of the machine. Lift the cast idle roll assembly and 7. Set one of the Readi-Reel
