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SVM160-B
April, 2005
™
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
importantly, think before you act
and be careful.
SERVICE MANUAL
Copyright © 2005 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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
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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
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.
kill.
3.a. 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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
4.c. 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 spatter or metal.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
5.b. 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 prod-
ucts.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
5.c. 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.
3.h. 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.
5.d. 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 are available from
your welding distributor or from the manufacturer.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
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iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. 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.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. 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.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. 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).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. 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.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
6.g. 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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
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.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
POWER MIG 300
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iv
iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
POWER MIG 300
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6
6
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
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Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories...........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Theory of Operation..............................................................................................................Section E
Troubleshooting and Repair ................................................................................................Section F
How to Use Troubleshooting Guide............................................................................................F-2
Troubleshooting Guide................................................................................................................F-4
Test Procedures........................................................................................................................F-14
Replacement Procedures .........................................................................................................F-36
Electrical Diagrams ..............................................................................................................Section G
Parts Manual.....................................................................................................P409 & P202-C Series
POWER MIG 300
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A-1
A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
INSTALLATION......................................................................................................................Section A
Technical Specifications .............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Input Supply Connection Diagram..............................................................................................A-4
Gun and Cable Installation..........................................................................................................A-5
POWER MIG 300
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A-2
A-2
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
40%
Amps
Volts at Rated Amperes
32 Volts
208
300 Amps
300 Amps
230Amps
230/460/575
208/230/460/575
60%
100%
32 Volts
29 Volts
OUTPUT
Welding Current Range (Continuous) Maximum Open Circuit Voltage
5 – 350 Amps 67 Volts
Welding Voltage Range
10-45 Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES - SINGLE PHASE
Input Voltage/
230Amps @
300Amps @
75°C Copper Wire
Fuse
or
Frequency (Hz)
29 Volts
32 Volts
AWG (IEC)
Sizes (MM2)
(100% Duty Cycle)
(60% Duty Cycle)
Breaker Size
208/60*
230/60
460/60
575/60
48 A
43 A
22 A
17 A
72 A
62 A
31 A
25 A
6 (16 mm2)
6 (16 mm2)
10 (6 mm2)
12 (2.5 mm2)
90 A
80 A
50 A
35 A
NOTE: Use #10 AWG Grounding Wire
*For 208V Input ONLY: The duty Cycle Rating at 300 Amps is 40%
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
31.79 in
808 mm
18.88 in
480 mm
38.78 in
985 mm
255 Ibs
116 kg
WIRE SPEED RANGE
Wire Speed
50 – 700 IPM (1.27 – 17.8 m/minute)
POWER MIG 300
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A-3
A-3
INSTALLATION
ONLY QUALIFIED PERSONNEL SHOULD
INSTALL, USE OR SERVICE THIS EQUIP-
MENT.
Read entire installation section before starting
installation.
SAFETY PRECAUTIONS
UNCRATING THE POWER MIG 300
WARNING
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 Bottle Platform) holding the machine to
the skid. Roll the machine off the skid assembly.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrode with skin or
wet clothing.
• Insulate yourself from work and
ground.
LOCATION
• Always wear dry insulating
gloves.
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
out the front. A location that minimizes the amount of
smoke and dirt drawn into the rear louvers reduces
the chance of dirt accumulation that can block air pas-
sages and cause overheating.
• Do not use AC welder if your
clothing, cloves or work area is
damp or if working on, under or
inside work piece.
Use the following equipment:
- Semiautomatic DC constant volt-
age (wire) welder.
INPUT POWER, GROUNDING AND
CONNECTION DIAGRAMS
- DC manual (stick) welder.
- AC welder with reduced voltage
control.
• Do not operate with panels
removed.
• Disconnect input power before
servicing.
1. Before starting the installation, check with the local
power company if there is any question about
whether your power supply is adequate for the volt-
age, amperes, phase, and frequency specified on
the welder nameplate. Also be sure the planned
installation will meet the U.S. National Electrical
Code and local code requirements. This welder
may be operated from a single phase line or from
one phase of a two or three phase line.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone and general area.
2. The POWER MIG 300 is supplied connected for
230 Volt Input. If the welder is to be operated on
another voltage, it must be reconnected according
to the instructions in Figure A.1
WELDING SPARKS can
cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed contain-
ers.
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protec-
tion.
Observe all safety information through-
out this manual.
-----------------------------------------------------------
POWER MIG 300
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A-4
A-4
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.
Using the instructions in Figure A.2, have a quali-
fied electrician connect the receptacle or cable to
the input power lines and the system ground per
the U.S. National Electrical Code and any applica-
ble local codes. See “Technical Specifications”
at the beginning of this chapter for proper wire
sizes. For long runs over 100ft. (30.48m), larger
copper wires should be used. Fuse the two hot
lines with super lag type fuses as shown in the fol-
lowing diagram. The center contact in the recepta-
cle is for the grounding connection. A green wire in
the input cable connects this contact to the frame of
the welder. This ensures proper grounding of the
welder frame when the welder plug is inserted into
the receptacle.
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.
POWER MIG 300
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A-5
A-5
INSTALLATION
GUN & CABLE ASSEMBLY INSTALLED
GUN AND CABLE INSTALLATION
INTO THE POWER MIG
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..
1. Unscrew knurled screw on the drive unit front end
(inside wire feed compartment) until tip of screw no
longer protrudes into gun opening as seen from
front of machine.
2. Insert the male end of gun cable into the female
casting through opening in front panel. Make sure
connector is fully inserted and tighten knurled
screw.
WARNING
3. Connect the gun trigger connector from the gun
and cable to the mating receptacle inside the com-
partment located above the gun connection made
in step 2 above. Make sure that the key ways are
aligned, insert and tighten retaining ring.
Turn the welder power switch off before installing
gun and cable.
LINER INSTALLATION AND TRIMMING
INSTRUCTION (SEE FIGURE A.3)
SHIELDING GAS
1. Remove the gas nozzle.
(For Gas Metal Arc Welding Processes)
2. Remove the gas diffuser from the gun tube. If gas
diffuser contains a small set screw, loosen the set
screw.
Customer must provide cylinder of appropriate type
shielding gas for the process being used.
3. Lay gun and cable out straight on a flat surface.
Loosen set screw of the connector on the back end
of the gun.
A gas flow regulator, for CO2 or Argon blend gas, and
an inlet gas hose are factory provided with the
POWER MIG 300.
4. Insert the untrimmed Liner into the back end of the
gun.
WARNING
CYLINDER may explode if
damaged.
5. Seat Liner bushing into back of gun. Secure Liner
by tightening set screw. Do not install the gas dif-
fuser at this time.
• Gas under pressure is explosive. Always
keep gas cylinders in an upright position
and always keep chained to undercarriage
or stationary support. See American
National Standard Z-49.1, “Safety in
Welding and Cutting” published by the
American Welding Society.
6. Lay the cable straight and trim Liner to 9/16”.
Remove burrs.
7. Secure the gas diffuser into the tube.
Install shielding gas supply as follows:
1. Set gas cylinder on rear platform of POWER MIG
300. Hook chain in place to secure cylinder to rear
of welder.
8. Tighten the set screw against the Liner.
CAUTION
This screw should only be gently tightened. Over
tightening will split or collapse the liner and cause
poor wire feeding.
2. Remove the cylinder cap. Inspect the cylinder
valves and regulator for damaged threads, dirt,
dust, oil or grease. Remove dust and dirt with a
clean cloth.
------------------------------------------------------------------------
FIGURE A.3
FEEDR END
CABLE HANDLE
GUN HANDLE
GUN TUBE
INSULATION TUBE
BRASS CABLE
CONNECTOR
9/16 (14.3mm)
LINER TRIM
LENGTH
MOLDED GAS PLUG
SET SCREW
CLAMPING SCREW
SET SCREW
GAS DIFFUSER
LINER ASSEMBLY (LINER BUSHING TO BE SEATED
TIGHT AGIANST BRASS CABLE CONNECTOR)
NOZZLE INSULATION
GAS NOZZLE
POWER MIG 300
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A-6
A-6
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 valve and
tighten the union nut(s) securely with a wrench.
NOTE: If connecting to 100% CO2 cylinder, insert
regulator adapter between regulator and cylinder
valve. If adapter is equipped with a plastic washer,
be sure it is seated for connection to the CO2 cylin-
der.
5. Attach one end of the inlet gas hose to the outlet
fitting of the flow regulator, the other end to the
POWER MIG 300 rear fitting, and tighten the union
nuts securely with a wrench.
6. Before opening the cylinder valve, turn the regula-
tor adjusting knob counterclockwise until the
adjusting spring pressure is released.
7. Standing to one side, open the cylinder valve slow-
ly a fraction of a turn. When the cylinder pressure
gauge pointer stops moving, open the valve fully.
WARNING
Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
stand to one side.
------------------------------------------------------------------------
8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making the weld.
POWER MIG 300
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B-1
B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Definitions of Welding Modes.....................................................................................................B-2
Product Description....................................................................................................................B-3
Controls and Settings..........................................................................................................B-3/B-4
Setting and Configuring..............................................................................................................B-5
Multi-Process Panel Functions...................................................................................................B-6
Arc Control..................................................................................................................................B-7
Wire Drive Roll ............................................................................................................................B-8
Changing Drive and Idle Roll Sets ..............................................................................................B-9
Feeding Wire Electrode.............................................................................................................B-10
Pulse Welding ...........................................................................................................................B-11
Pulse-On-Pulse.........................................................................................................................B-12
Power Mode..............................................................................................................................B-13
POWER MIG 300
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B-2
B-2
OPERATION
Read entire Operation section before
operating the POWER MIG 300.
COMMON WELDING ABBREVIA-
TIONS
WARNING
ELECTRIC SHOCK can kill.
WFS
• Wire Feed Speed
• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
CC
• Constant Current
CV
• Always wear dry insulating
gloves.
• Constant Voltage
GMAW (MIG)
• Gas Metal Arc welding
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
GMAW-P (MIG)
• Gas Metal Arc welding-(Pulse)
• Use ventilation or exhaust to
remove fumes from breathing
zone.
GMAW-PP (MIG)
• Gas Metal Arc welding-(Pulse-on-Pulse)
WELDING SPARKS can
cause fire or explosion.
GTAW (TIG)
• Gas Tungsten Arc welding
• Keep flammable material away.
SMAW (STICK)
• Shielded Metal Arc welding
• Do not weld on closed contain-
ers.
FCAW (INNERSHIELD)
• Flux Core Arc Welding
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protec-
tion.
Observe all safety information throughout
this manual.
DEFINITIONS OF WELDING MODES
NON-SYNERGIC WELDING MODES
• A Non-synergic welding mode requires all welding
process variables to be set by the operator.
SYNERGIC WELDING MODES
• A Synergic welding mode offers the simplicity of
single knob control. The machine will select the cor-
rect voltage and amperage based on the wire feed
speed (WFS) set by the operator.
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B-3
B-3
OPERATION
Other features
PRODUCT DESCRIPTION
Optional kits are available for push-pull welding, spool
gun operation, push feeding of 3/64 aluminum with the
standard POWER MIG 300 gun and wire feeder. A
Dual Cylinder Mounting Kit is also offered.
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-on-Pulse and Power Mode welding
processes. See the descriptions for Pulse on
Pulse™and Power Mode welding processes later in
this section.
CONTROLS AND SETTINGS
(See Figure B.1)
1. WIRE FEED SPEED (WFS) / AMP METER - This
meter displays either the WFS or current value
(Amps) depending on the status of the machine.
Located below the display is the text "WFS" and
"Amps." An LED light is illuminated to the left of one
of these units to indicate the units of the value dis-
played on the meter.
Mode #5 and mode #6 are non-synergic CV GMAW
modes for bare and flux cored wires, respectively. In
these modes, the user presets the wire feed speed
(WFS) on the left meter and the welding voltage on
the right. These two settings are independent; that is,
if the WFS is changed the voltage will remain con-
stant, or vice versa.
• Prior to CV operation, the meter displays the
desired preset WFS value.
• Prior to CC-Stick and CC-GTAW operation, the
meter displays the preset current value.
• During Welding, the meter displays actual average
amps.
• After welding, the meter holds the actual current
value for 5 seconds. During this time, the display
is blinking to indicate that the machine is in the
"Hold" period. Output adjustment while in the
"Hold" period results in the "prior to operation"
characteristics stated above.
• After the 5 second "Hold" period, the meter dis-
plays the set WFS (CV modes) or Amp (CC
modes) value.
All of the other mode numbers designated as "CV" are
synergic. Again, WFS is shown on the left meter and
voltage is shown on the right meter. However, in using
these modes, the WFS is preset and the voltage is
preset only once. Now, when the WFS is changed, the
voltage will change with it, so that the arc appearance
and arc length will stay the same without the necessity
to re-adjust the voltage.
The modes shown as "GMAW-P" or " GMAW-PP" are
all synergic pulsed modes. In these modes WFS is
shown on the left meter and "Trim" is shown on the
right meter. The user adjusts WFS to obtain an arc
with the correct arc energy for the material thickness
being welded. The Trim, which is adjustable from val-
ues of –1.5 to 0 (OFF) and up to +1.5 controls the arc
length. Higher values of Trim give longer arc lengths.
Once the user has adjusted the Trim for one WFS, the
power supply will synergically change many variables
so that, as the WFS is changed, the arc length and
arc appearance will remain the same. The synergic
modes are usable with both push and push – pull
torches, as described later in this Manual. When using
a spool gun, however, although the synergic pulsed
modes are still accessible, they must be used in a
non-synergic manner as described in the Accessory
Section.
FIGURE B.1
The digital microcomputer based control system
allows easy and accurate adjustment of weld parame-
ters through the multi-process panel located on the
front of the machine. The POWER MIG 300 is
equipped with a 6-pin and 7-pin connector to allow
operation of a push-pull gun for feeding aluminum
wires, a spool gun, remotes, and a foot amptrol.
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B-4
B-4
OPERATIONS
5. MULTI-PROCESS PANEL - This panel enables selection
of weld modes as well as adjustment of certain weld
parameters within each weld mode.
2. VOLT / TRIM METER - This meter displays either
the voltage or trim value depending on the status of
the machine. Located below the display is the text
"Volts" and "Trim." An LED light is illuminated to
the left of one of these in order to indicate the units
of the value displayed in the meter.
The eight discrete LED’s are used to identify which selec-
tion will be shown on the display. The possible selections
are:
CV Processes
• Weld Mode (Process selection choices)
• Preflow / Postflow
• Prior to GMAW and FCAW operation, the meter
displays the desired preset Voltage value.
• Prior to synergic GMAW-P and GMAW-PP oper-
ation, the meter displays the desired preset Trim
value. Trim adjusts the synergic default voltage
as a percentage of that voltage. A trim value of 1
is the default and results in the recommended
voltage setting for a given wire feed speed.
Adjusting trim to a value of .95, adjusts the volt-
age to 95% of the recommended voltage.
• During Welding, the meter displays actual aver-
age volts.
• After welding, the meter holds the actual voltage
value for 5 seconds. During this time , the display
is blinking to indicate that the machine is in the
"Hold" period. Output adjustment while in the
"Hold" period results in the "prior to operation"
characteristics stated above.
• Run-In
• Start
• Arc Control
• Crater
• Burnback
• Spot
Choice of weld parameters
that can be adjusted.
Complete descriptions of
each parameter are found
}
later in this section.
Only one LED will be illuminated at any time. The Weld
Mode attribute will always be a valid selection (the other
attributes may not be available in all processes).
5A. SELECT Toggle Switch
• This switch toggles through the 8 selections detailed
above the switch.
• A red LED is located next to each possible selection
and is illuminated when that choice can be changed.
5B. Display Meter
• This meter displays the active weld mode (a set of
weld parameters that have been determined to pro-
vide the recommended results for a particular welding
process) when the “Weld Mode” LED is illuminated or
when any one of the other seven LED’s is illuminated
the meter indicates what value that welding parame-
ter has been set to.
• After the 5 second "Hold" period, the meter dis-
plays the set Voltage (GMAW, FCAW) or Trim
(GMAW-P) value.
CC Processes
• The meter displays the status of the output.
5C. SET Toggle Switch
• This switch adjusts (up or down) the value shown on
the display meter. When the WELD MODE LED is illu-
minated, this switch is changing the weld mode of the
machine. The most commonly used modes are dis-
played in the chart on the right half of the Multi-
Process Panel.
• When output is enabled, the meter will display "ON."
• When there is no output, the meter will display "OFF."
3. OUTPUT CONTROLS - The POWER MIG 300 has 2
encoder knobs to adjust weld parameters.
If the LED next to
a
weld parameter
• Each encoder changes the displayed value of the meter
located directly above that encoder.
(Preflow/Postflow, Run-In, Start, etc.) is illuminated,
the SET switch will adjust the setting of that specific
weld parameter. The setting is shown on the display
meter.
• In CC-GTAW modes, the left encoder sets the maxi-
mum welding current. Full depression of a foot or hand
amptrol results in the preset level of current.
6. ON/OFF POWER SWITCH
• In CC-Stick and CC-GTAW, the right encoder activates
and de-activates the output. Turning the encoder clock-
wise enables the output if not using a remote trigger
device. To de-energize the output, turn the encoder
counter-clockwise. The display above will indicate the
"ON" or "OFF" status of the output.
4. THERMAL - This status light illuminates when the power
source has been driven into thermal overload.
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B-5
B-5
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 displays a weld mode num-
ber corresponding to a CC or CV welding process as
detailed by the chart on the right side of the panel. In the
example shown in Figure B.2 “3” is displayed above the
SET switch. This means that the machine is set for CC-
GTAW (TIG) welding.
• Toggle the SELECT switch to activate the "weld parame-
ters" for the selected weld mode.
• Set each parameter using the SET switch to adjust the
parameter displayed on the display meter.
NOTE: If the LED next to the weld parameter is flashing, the
WFS/AMP and/or the Volt/Trim values can also be adjusted
for that parameter using the control knobs below each dis-
play meter. An LED below each of the displays will also be
flashing to indicate which value is adjustable.
The Table B.1 shows which weld parameters are adjustable
for a given weld mode. The weld parameters are detailed
later in this section.
FIGURE B.2
3
TABLE B.1
PREFLOW /
POSTFLOW
-----
RUN IN START ARC CONTROL
CRATER
BURNBACK
SPOT
CC-STICK
CC-GTAW
CV-FCAW
CV-GMAW
CV-GMAW-P
POWER
-----
-----
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
-----
Yes
Yes
Yes
Yes
-----
-----
Yes
Yes
Yes
Yes
-----
-----
Yes
Yes
Yes
Yes
-----
-----
Yes
Yes
Yes
Yes
Yes
-----
Yes
Yes
Yes
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B-6
B-6
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-
pendent of the Welding or Start wire feed speed. Setting a
Run-In WFS lower than the welding WFS avoids stubbing
problems when starting the arc.
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 machine. It
describes the type of process (CV, CC, synergic
GMAW), type of metal (mild steel, stainless steel, alu-
minum), type of shielding gas and size of electrode rec-
ommended for a particular mode.
• Run-In is selected by toggling the SELECT switch until the
LED next to RUN-IN is lit. A Run-In WFS may be adjusted
using the SET switch on the Multi-Process Panel. The
Display meter on the Multi-Process Panel will indicate the
run-in speed. Do not use the Output Control Knob on the
upper case front to adjust the WFS. This will change the
welding WFS displayed in the meters on the upper case
front.
The Weld Mode selection is enabled by toggling the
SELECT switch until the LED next to Weld Mode is lit. A
Weld Mode number will be displayed on the display
meter. Toggling the SET switch up or down will increase
or decrease the WELD MODE number displayed. The
machine will change to the selected weld mode after two
seconds of SET switch inactivity. If the SELECT switch is
changed before two seconds of SET switch inactivity, the
machine will not change modes. The last active Weld
Mode will be saved at power down so that it will be
selected with the next power up of the machine.
• The default value for Run-In is "OFF."
• Run-In speed is adjustable from 50 ipm to 150 ipm
(Inches per Minute).
Start Procedure
This machine provides the option of setting a Starting
Procedure to start the weld, and from there, to ramp to the
welding procedure over a specified amount of time.
Typically starting on a higher starting procedure than the
welding procedure is known as a “Hot Start”. Setting a start-
ing procedure lower than the welding procedure is known as
a “Cold Start”.
Preflow / Postflow
• The Preflow setting allows a time to be selected for
shielding gas to flow after the trigger is pulled and prior
to wire feeding and establishing an arc.
For SMAW (Stick) welding setting a “Hot Start” helps to
minimize stubbing the electrode.
• The Postflow setting allows a time to be selected for
shielding gas to continue to flow after the trigger is
released and output current is turned off.
For GTAW (TIG) welding setting a “Cold Start” minimizes
burn-through of thin materials when not using a manual
amperage control.
• The Preflow timer will be selected by toggling the
SELECT switch until the LED next to PREFLOW
/POSTFLOW is lit. The display meter will read Pre. The
present Preflow time will be displayed and can be
changed by positioning the SET switch up or down.
For Wire Feed welding using a start procedure can help
improve starting characteristics. A good example is when
welding aluminum. Aluminum’s high thermal conductivity
results in heat spreading around the plate very fast.
Therefore more energy is necessary at the very beginning to
heat up the starting point of the weld. Once the welding
begins, it is not necessary to give this extra heat anymore
so a ramp down to the welding procedure is necessary.
• The Postflow timer will be selected by pressing down
the SELECT switch an additional time. The LED next
to PREFLOW / POSTFLOW will remain lit; but the dis-
play meter will now read Pos. The present Postflow
time will be displayed and can be changed by position-
ing the SET switch up or down.
To set a Start Procedure begin by using the SELECT switch
to select the Start LED. Using the SET switch, enter the
desired Start ramp time duration (its available values range
from 0.01 seconds to 0.50 seconds in increments of 0.01
seconds or the default value of OFF). This value will be dis-
played on the digital meter of the multiprocess panel (See
Figure B.2).
• The default value for both Preflow and Postflow is
"OFF" (0 seconds).
• Preflow can be adjusted from 0 to 2.5 seconds in 0.1
second increments.
• Postflow can be adjusted from 0 to 10.0 seconds in 0.1
second increments.
After setting the Start time also set the WFS, and
voltage/trim. The way to know what information needs
to be entered is to look for flashing LED’s. If an LED is
flashing that parameter value needs to be entered.
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B-7
B-7
OPERATION
Carbon steel electrodes employed in GMAW-S usually per-
form best when the droplet size is regulated by pinch to
reduce the droplet size transferred with each short-circuit
event.
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.
When welding with solid stainless steel types of electrodes it
is usually desirable to increase the energy delivered to the
arc. High percentage argon blends with a 2 % addition of
oxygen or a three part shielding gas blend comprised of
90% Helium + 7.5% Argon + 2.5 % carbon dioxide are usu-
ally employed. The added energy is associated, in this sce-
nario, with increasing the inductance (negative numeric val-
ues). By adding to the energy level the weld bead appear-
ance improves – spatter levels decrease and wetting action
at the toes of a fillet weld increases. The arc is softer with
the higher inductance setting and the arc lends itself to
faster travel speed.
In SMAW (STICK mode), arc control adjusts the arc force. It
can be set to the lower range for a soft and less penetrating
arc characteristic (negative numeric values) or to the higher
range (positive numeric values) for a crisp and more pene-
trating arc. Normally, when welding with cellulosic types of
electrodes (E6010, E7010, E6011), a higher energy arc is
required to maintain arc stability. This is usually indicated
when the electrode sticks to the work-piece or when the arc
pops-out during manipulative technique. For low hydrogen
types of electrodes (E7018, E8018, E9018, etc.) a softer arc
is usually desirable and the lower end of the Arc Control
suits these types of electrodes. In either case the arc con-
trol is available to increase or decrease the energy level
delivered to the arc.
In GMAW-P, the pulsed spray mode of metal transfer, the
Arc Control is, once again, used to increase and decrease
the focus of the energy delivered to the arc. Increasing the
setting in the range of +1 to +10 results in an increase in
pulsed frequency, and the effect is to narrow the arc cone
and concentrate the available energy to a smaller area.
Decreasing the Arc Control setting from –1 to –10 results in
a reduction of pulsed frequency – the result is a broader arc
cone, which creates a wider weld bead.
In GMAW-S, the short-circuiting mode of metal transfer, the
Arc Control features the ability to increase or decrease the
energy level at the arc. Setting the arc control from 1 to 10
decreases energy, and setting the Arc Control from 0 to –10
increases the energy delivered to the arc.
Solid carbon steel electrodes in a range from .025"- .045" (.6
mm – 1.1 mm) are nominally used, and the shielding gas
blend for GMAW-S is usually 100% carbon dioxide or a
blend of argon and carbon dioxide. The Arc Control in this
scenario is set to control the droplet size and more pinch is
added (increasing pinch reduces energy to the arc) to
achieve the "bacon frying" sound associated with this mode
of metal transfer.
Important to note here is that if a component of a pulsed
waveform is increased, then another must be decreased.
Adding pulsed frequency through an increase in the Arc
Control setting, then also results in a proportional decrease
in background current. If this were not the case, then the arc
would become too long, with too much energy, and the arc
would be unusable.
TABLE B.2-ARC CONTROL SETTINGS BY PROCESS
PROCESS
ARC
SETTING
APPLICATION AND
RESULT
CONTROL
SYNONYM
Arc Force
SMAW (STICK)
Lower (-1 to -10) for
low hydrogen types of
electrodes. Higher (+1
to +10) for cellulosic
and other types.
Minus settings are soft
and buttery for low
hydrogen electrodes.
Plus settings are harsh
and digging for other
types of electrodes.
The minus settings
result a more fluid
GMAW – S (Short
circuiting metal
transfer
Inductance or
Pinch Control
Setting -1 to -10 for
softer higher energy
arc. Setting +1 to +10
for a crisper lower
energy arc.
puddle and larger
droplet size. The lower
settings reduce the
droplet size and reduce
energy to the arc.
GMAW – P (Pulsed
spray metal transfer)
Pulsed frequency
control
Minus settings reduces
frequency. Plus
settings increase
frequency.
Wider arc cone and
weld bead. Narrower
arc cone and narrower
weld bead.
Pulse – on –Pulse™ Pulsed frequency
(Aluminum Only) array control
Minus settings result in
lower array frequency
and the plus settings
increase the array
frequency.
Minus settings result in
a wider bead with more
distinct ripples. Plus
settings narrow the
resultant bead and the
ripples are less distinct.
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B-8
B-8
OPERATION
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 distinct and the arc cone narrows. When the
Arc Control is set from -1 to -10 the Pulse on Pulse arrays
decrease in frequency, the weld bead ripples become more
distinct, and the bead width increases.
• In the GMAW, FCAW, and Power weld modes, crater
WFS and voltage are adjustable using the control knobs
on the upper case front. This in indicated by the flashing
LED’s next to "WFS" and "VOLTS."
• In the GMAW-P weld modes, Crater WFS and trim are
adjustable. This is indicated by the flashing LEDs next to
"WFS" and "TRIM."
In GMAW-PP mode, arc control adjusts the modulation fre-
Burnback
quency, which means the speed at which the ripples are
produced in the weld. (See Pulse-on-Pulse description later
in this section.) When faster travel speeds are desired, arc
control needs to be set higher. When slower travel speeds
are desired, arc control needs to be set lower.
Setting the Burnback means setting the adjustable time
delay between turning off the wire feeding and turning off
the arc. Burnback helps to prevent wire sticking to the pud-
dle.
• The Burnback feature will allow current to continue to flow
for a specified time period at the end of a weld after wire
feeding has stopped.
• The Arc-control adjustment is selected by toggling the
SELECT switch until the LED next to ARC CONTROL is
lit. The Arc-control value will be displayed. Arc-control can
be adjusted by toggling the SET switch up or down.
• The default value is "OFF."
• The Burnback timer will be selected by toggling the
SELECT switch until the LED next to BURNBACK is lit. A
burnback time may be set using the SET switch.
Crater
The crater is the end of the weld, which normally solidifies
creating a concave surface. This can result in stresses that
can cause cracks in the center of the crater. The purpose of
the Crater control is to fill up the crater, so that its surface
becomes flat.
• The default value is "OFF" (0 seconds).
• Burnback time is adjustable from 0 to 0.25 seconds in
0.01 second increments.
Spot
Crater control in this machine is more efficient than in other
machines. Normally, in other machines, the crater filling pro-
cedure is a step down from the welding WFS to the crater
filling WFS. In this machine instead of a step down, the tran-
sition is a ramp down, which results in a more controlled fill-
ing up of the crater and so, less stresses present in it.
The Spot Timer adjusts arc on-time for spot or tack welds.
• With the Spot feature active (Spot time selected), when
the trigger is pulled and the arc is established, the weld
will continue until the expiration of the spot timer and the
next active state will be enabled (crater or burnback). The
trigger must be released and pulled again for another Spot
cycle.
The values to enter are first the desired time to stay at the
Crater settings and the desired WFS and voltage/trim to fill
the crater.
• The Spot timer is selected by toggling the SELECT switch
until the LED next to SPOT is lit. The present SPOT time
will be displayed and can be changed by toggling the SET
switch up or down.
• The Crater timer is selected by toggling the SELECT
switch until the LED next to CRATER is lit and flashing. A
crater time may be set using the SET switch.
• The default value is "OFF" (0 seconds).
• The available values for crater control time go from "Off"
to 0.1 seconds and from there to 10.0 seconds in incre-
ments of 0.1 seconds.
• Spot can be adjusted from 0 to 10.0 seconds in 0.1 sec-
ond increments.
• The Crater function offers the ability to set an endpoint for
WFS and Voltage that will be reached over a specified
time period. At the end of the weld when the trigger is
released, the crater timer will begin and the WFS and
Volts settings will ramp down from the Weld Mode WFS
and Voltage settings to the Crater WFS and Voltage set-
tings over the time selected. This creates a ramp down of
the WFS and Volts during the Crater time.
WIRE DRIVE ROLL
The drive rolls installed with the POWER MIG 300 have two
grooves, one side for .030" (0.8mm) solid steel electrode,
and the other for the .045”(1.2mm) electrode. The actual
drive roll size is stenciled on the side opposite of its groove.
If feeding problems occur, a check may be required to make
sure that the wire size and the drive roll size matches. See
"Procedure for Changing Drive Rolls" in this section.
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OPERATION
B-9
B-9
5. Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.
PROCEDURE FOR CHANGING
DRIVE AND IDLE ROLL SETS
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.
1. Turn off the power source.
2. Release the pressure on the idle roll by swinging
the adjustable pressure arm down toward the back
of the machine. Lift the cast idle roll assembly and
allow it to sit in an upright position.
7. Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.
3. Remove the outside wire guide retaining plate by
loosening the two large knurled screws.
8. Lower the Readi-Reel to depress the retaining spring
and align the other inside cage wires with the grooves
in the molded adapter.
4. Twist the drive roll retaining mechanism to the
unlocked position as shown below and remove the
drive roll. (See Figure B.3)
9. Slide cage all the way onto the adapter until the
retaining spring "pops up" fully.
FIGURE B.3
CAUTION
Check to be sure the retaining ring has fully returned to the locking
position and has securely locked the Readi-Reel cage in place.
Retaining spring must rest on the cage, not the welding electrode.
-----------------------------------------------------------------------------------------------
10. To remove Readi-Reel from Adapter, depress retain-
ing spring tab with thumb while pulling the Readi-
Reel cage from the molded adapter with both hands.
Do not remove adapter from spindle.
LOCKED POSITION
UNLOCKED POSITION
5. Remove the inside wire guide plate.
6. Replace the drive and idle rolls and inside wire
guide with a set marked for the new wire size.
NOTE: Be sure that the gun liner and contact tip
are also sized to match the selected wire size.
FIGURE B.4
7. Manually feed the wire from the wire reel, over the
drive roll groove and through the wire guide and
then into the brass bushing of the gun and cable
assembly.
8. Replace the outside wire guide retaining plate by
tightening the two large knurled screws. Reposition
the adjustable pressure arm to its original position
to apply pressure. Adjust pressure as necessary.
TO MOUNT 10 to 44 Lb. (4.5-20 kg) SPOOLS (12"/300
mm Diameter) or 14Lb.(6 Kg) Innershield Coils:
WIRE REEL LOADING - READI-REELS,
SPOOLS OR COILS
(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil
Adapter must be used).
To Mount a 30 Lb. (14 kg) Readi-Reel Package
(Using the Molded Plastic K363-P Readi-Reel
Adapter):
1. Open the Wire Drive Compartment Door
1
. Open the Wire Drive Compartment Door
2. Depress the Release Bar on the Retaining Collar
and remove it from the spindle.
2. Depress the Release Bar on the Retaining Collar
and remove it from the spindle.
3. Place the spool on the spindle making certain the
spindle brake pin enters one of the holes in the
back side of the spool (Note: an arrow mark on the
spindle lines up with the brake holding pin to assist
in lining up a hole). Be certain the wire comes off
the reel in a direction so as to de-reel from the top
of the coil.
3. Place the Optional Adapter on the spindle
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.
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B-10
B-10
OPERATION
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.
1. Press end of gun against a solid object that is elec-
trically isolated from the welder output and press
the gun trigger for several seconds.
2. If the wire “birdnests”, jams or breaks at the drive
roll, the idle roll pressure is too great. Back the
adjustment knob out 1/2 turn, run new wire through
gun, and repeat above steps.
FEEDING WIRE ELECTRODE
WARNING
When triggered, the electrode and drive mecha-
nism are electrically “hot” relative to work and
ground and remain “hot” several seconds after
the gun trigger is released.
3. If the only result was drive roll slippage, loosen the
adjustment knob on the conductor plate and pull
the gun cable forward about 6" (15 cm). There
should be a slight waviness in the expose wire. If
there is not waviness, the pressure is too low.
Tighten the adjustment knob 1/4 turn, reinstall the
gun cable and repeat the above steps.
------------------------------------------------------------------------
NOTE: Check that drive rolls, guide plates and gun
parts are proper for the wire size and type being used.
Refer to Table C.1 in ACCESSORIES section.
AVOIDING WIRE FEEDING
PROBLEMS
1. Turn the Readi-Reel or spool until the free end of
the electrode is accessible.
Wire feeding problems can be avoided by observing
the following gun handling procedures:
2. While securely holding the electrode, cut off the
bent end and straighten the first six inches. (If the
electrode is not properly straightened, it may not
feed properly through the wire drive system).
a. Do not kink or pull cable around sharp corners.
b. Keep the gun cable as straight as possible when
welding or loading electrode through cable.
3. Release the pressure on the idle roll by swinging
the adjustable pressure arm down toward the back
of the machine. Lift the cast idle roll assembly and
allow it to sit in an upright position. Leave the outer
wire guide plate installed. Manually feed the wire
through the incoming guide bushing and through
the guide plates (over the drive roll groove). Push a
sufficient wire length to assure that the wire has fed
into the gun and cable assembly without restriction.
Reposition the adjustable pressure arm to its origi-
nal position to apply pressure to the wire.
c. Do not allow dolly wheels or trucks to run over
cables.
d. Keep cable clean by following maintenance instruc-
tions.
e. Use only clean, rust-free electrode. Lincoln elec-
trodes have proper surface lubrication.
f. Replace the contact tip when the arc starts to
become unstable or the contact tip end is fused or
deformed.
4. Press gun trigger to feed the electrode wire through
the gun.
g. Keep wire reel spindle brake tension to the mini-
mum required to prevent excess reel over-travel
which may cause wire “loop-offs” from the coil.
IDLE ROLL PRESSURE SETTING
The idle roll pressure adjustment knob is set at the
factory at the #2 hash mark. This is an approximate
setting. The optimum idle roll pressure varies with
type of wire, wire diameter, surface conditions, lubri-
cation, and hardness. As a general rule, hard wires
may require greater pressure, and soft, or aluminum
wire, may require less pressure than the factory set-
ting. The optimum idle roll setting can be determined
as follows:
h. Use proper drive rolls and wire drive/idle roll pres-
sure for wire size and type being used.
POWER MIG 300
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B-11
B-11
OPERATION
Pulsed MIG is an advanced form of welding that takes
the best of all the other forms of transfer while minimiz-
ing or eliminating their disadvantages. Unlike short cir-
cuit, pulsed MIG does not create spatter or run the risk
of cold lapping. The welding positions in pulsed MIG
are not limited as they are with globular or spray and its
wire use is definitely more efficient. Unlike the spray arc
process, pulsing offers controlled heat input that allows
better welding on thin materials, lower wire feed speeds
and leads to less distortion and improved overall quality
and appearance. This is especially important with stain-
less, nickel and other alloys that are sensitive to heat
input.
SPECIAL WELDING PROCESSES
AVAILABLE 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 at
regularly spaced intervals. In the time between pulses,
the welding current is reduced and no metal transfer
occurs.
Pulsed-arc transfer is obtained by operating a power
source between low and high current levels. The high
current level or “pulse” forces an electrode drop to the
workpiece. The low current level or “background”
maintains the arc between pulses. (See Figure B.5).
In GMAW-P mode, arc control adjusts the background
current and frequency of the wave. When arc control
goes up, the frequency increases thus increasing the
droplet transfer rate.
FIGURE B.5
EACH PULSE DELIVERS ONE DROPLET OF WELD MATERIAL
FREQUENCY
SPRAY TRANSITION
CURRENT
POWER MIG 300
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B-12
B-12
OPERATION
When Arc Control is used in the Pulse on Pulse
modes, it does the same things it does in the other
pulsed modes: decreasing the Arc Control decreases
the droplet transfer and weld deposition rate.
Increasing the Arc Control increases the droplet trans-
fer and weld deposition rate. Since Arc Control varies
weld droplet transfer rate, the Arc Control can be used
to vary the ripple spacing in the weld bead.
PULSE-ON-PULSE™ (GMAW-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 single pulse type normally used in
GMAW-P. A number of high energy pulses are used
to obtain spray transfer and transfer metal across the
arc. Such pulses are shown in Figure B.6. After a
number "N" of such pulses, depending on the wire
feed speed used, an identical number "N" of low ener-
gy pulses are performed. These low energy pulses,
shown in Figure B.6, do not transfer any filler metal
across the arc and help to cool the arc and keep the
heat input low.
BENEFITS OF PULSE ON PULSE FROM
LINCOLN ELECTRIC
• Excellent appearance of the weld bead
• Improved cleaning action
• Reduced porosity
FIGURE B.6
Table B.3 shows WFS and Trim settings for common
aluminum types and wire sizes when welding with
Pulse-on-Pulse. The welds made to obtain the values
in the table were fillet welds in the flat position. The
values in the table can be helpful as a starting point to
establish a welding procedure. From there, adjust-
ments need to be made to set the proper procedure
for each specific application (out-of-position, other
types of joints, etc.).
"N" PULSES
"N" PULSES
HIGH HEAT
PULSES
LOW HEAT
PULSES
PEAK
AMPS
BACKGROUND
AMPS
TIME
The Peak Current, Background Current, and
Frequency are identical for the high energy and low
energy pulses. In addition to cooling the weld down,
the major effect of the low energy pulses is that they
form a weld ripple. Since they occur at very regular
time intervals, the weld bead obtained is very uniform
with a very consistent ripple pattern. In fact, the bead
has its best appearance if no oscillation of the welding
gun ("whipping") is used.(See Figure B.7)
The comments on Table B.3 show values of WFS
below which it is not recommended to weld. The rea-
son is, that below these values the weld transfer will
change from a spray arc to a short-arc, which is not
advisable when welding aluminum.
FIGURE B.7
WELDING PROCEDURES FOR PULSE-ON-PULSE (TABLE B.3)
MATERIAL
Aluminum 4043
100% Ar.
E4043
Aluminum 4043
100% Ar.
E4043
Aluminum 5356
100% Ar.
E5356
Aluminum 5356
100% Ar.
E5356
GAS
WIRE
WIRE SIZE
WELD MODE
0.035
3/64
0.035
3/64
98
99
101
102
14 ga.
250 / 1.0
200 / 1.0
230 / 1.0
225 / 1.0
10 ga.
3/16
1/4
400 /1.0
550 / 1.0
600 / 1.0
280 / 1.0
340 / 1.0
400 / 1.0
425 / 1.0
670 / 1.0
700 / 1.0
400 / 1.0
500 / 1.0
550 / 0.9
Not Recommended
below 200 WFS
Not Recommended
below 100 WFS
Not Recommended
below 200 WFS
Not Recommended
below 200 WFS
COMMENTS
POWER MIG 300
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B-13
B-13
OPERATION
POWER MODE™
Start by setting the wire feed speed based upon mate-
rial thickness and appropriate travel speed. Then
adjust the Volts/Trim knob as follows:
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
in improved welding performance in two primary types
of applications.
• For steel, listen for the traditional “frying egg”
sound of a good short-arc MIG procedure to know
you have the process set correctly.
• For aluminum, simply adjust the Volts/Trim knob
until the desired arc length is obtained.
• Short Arc MIG at low procedure settings.
• Aluminum MIG welding.
Note the Volts/Trim display is simply a relative number
and DOES NOT correspond to voltage.
Power Mode™ is a method of high speed regulation
of the output power whenever an arc is established. It
provides a fast response to changes in the arc. The
higher the Power Mode Setting, the longer the arc. If a
welding procedure is not established, the best way to
determine the Power Mode Setting is by experimenta-
tion until the desired output result is established.
Some procedure recommendations appear in Table
B.4.
In the Power Mode two variables need to be set:
• Wire Feed Speed
• Power Mode Trim
Setting up a Power Mode procedure is similar to set-
ting a CV MIG procedure. Select a shielding gas
appropriate for a short arc process.
• For steel, use 75/25 Ar/CO2 shield gas.
• For Stainless, select a Helium blend Tri-Mix.
• For Aluminum, use 100% Ar.
RECOMMENDED WELDING PROCEDURES FOR POWER MODE - TABLE B.4
MATERIAL
WIRE
Aluminum 4043 Aluminum 5356
Mild Steel
L56
Mild Steel
L56
Mild Steel
L56
Mild Steel
L56
Mild Steel
L56
Mild Steel
L56
Stainless Steel Stainless Steel
E4043
0.035
E5356
0.035
E308L
0.030
E308L
0.035
WIRE SIZE
GAS
0.025
0.025
0.030
0.030
0.035
0.035
100% Ar.
100% Ar.
100% CO2
75/25 Ar/CO2
100 / 0.8
120 / 1.0
140 / 1.5
190 / 2.0
260 / 3.0
330 / 4.5
100% CO2
75/25 Ar/CO2
90 / 1.0
100% CO2
75/25 Ar/CO2
Tri-mix
Tri-mix
22 ga.
Not Recommended
120 / 1.0
140 / 1.7
190 / 2.0
260 / 3.0
330 / 5.0
Not Recommended
100 / 0.7
110 / 1.5
125 / 2.0
160 / 2.3
230 / 3.5
300 / 6.0
400 / 7.5
20 ga.
18 ga.
16 ga.
14 ga.
12 ga.
10 ga.
3/16
100 /1.0
110 / 1.5
125 / 2.0
160 / 2.3
230 / 3.5
300 / 6.0
400 / 7.0
80 / 1.5
110 / 2.0
140 / 2.5
210 / 3.0
270 / 5.0
325 / 6.5
50 / 0.5
110 / 2.0
130 / 2.7
190 / 3.5
230 / 6.0
300 / 7.0
100 / 2.5
125 / 3.0
160 / 3.8
200 / 5.0
240 / 6.5
100 / 2.5
125 / 3.0
160 / 3.5
200 / 4.5
240 / 7.0
400 / 2.0
400 / 2.5
500 / 7.0
570 / 9.0
500 / 7.0
600 / 7.8
1/4
700 / 9.1
Not
700 / 8.5
Not
Recommended Recommended
COMMENTS
below 400
WFS
below 400
WFS
POWER MIG 300
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B-14
B-14
NOTES
POWER MIG 300
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C-1
C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Drive Roll Kits .............................................................................................................................C-2
Push-Pull Feeding Connection Adapter Kit................................................................................C-3
POWER MIG 300
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C-2
C-2
ACCESSORIES
English Wire
Size
Metric Wire
DRIVE ROLL KITS
Length
Part No.
Size
10' (3.0 m)
12' (3.6 m)
15' (4.5 m)
K470-1
K470-7
K470-3
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 – .045"
0.9 – 1.2 mm
Wire
Size
Drive Roll Kit
MAGNUM GUN CONNECTION KIT
(Optional K466-6)
.023”-.030” (0.6-0.8 mm)
.035” (0.9 mm)
.045” (1.2 mm)
.040” (1.0mm)
KP1696-030S
KP1696-035S
KP1696-045S
KP-1696-2
Solid
Steel
Using the optional K466-6 Magnum Connection kit for
the POWER MIG permits use of standard Magnum
200, 300 or 400 gun and cable assemblies.
.035-.045” (0.9-0.2mm)
.035” (0.9 mm)
KP-1696-1
K1692-2 SPOOL GUN (PRINCETM XL)
When the POWER MIG Gun Selector Switch is in the
“Standard / Spool Gun” position, the POWER MIG pro-
vides gun trigger switch transfer between the Magnum
gun or the spool gun for the same polarity welding with
different wire and gas processes.
KP1697-035C
KP1697-045C
KP1695-3/64A
Cored
.045” (1.2 mm)
3/64” (1.2 mm)
Aluminum
*.035 Aluminum recommended for Push-Pull systems only.
3/64" (1.2 mm) ALUMINUM
FEEDING KIT (K2153-1)
CAUTION
This kit helps push feeding aluminum through stan-
dard machine feeder and gun. It provides gun and
wire drive conversion parts to weld with 3/64" (1.2
mm) aluminum wire. 5356 alloy aluminum wire is rec-
ommended for best push feeding performance.
Closing either gun trigger will cause the electrode of
both guns to be electrically “HOT”. Be sure unused
gun is positioned so electrode or tip will not contact
metal case or other metal common to work.
-----------------------------------------------------------------------
Because the control circuitry senses each gun through
its trigger leads, weld parameters are displayed and
adjustable for the last gun that was triggered.
Kit includes drive rolls and wire guide plate for the
wire drive, liner and two contact tips for the gun, along
with installation instructions.
1. Pulling the trigger for the built-in feeder gun
(Magnum 300):
K363P READI-REEL ADAPTER
The K363P Readi-Reel Adapter mounts to the 2"
spindle. It is needed to mount the 22-30 lb. Readi-
Reels.
•
•
Disables spool gun operation.
Changes the displays of the POWER MIG 300 to
correspond to feeder gun operation.
•
Closing feeder gun trigger starts feeder gun weld-
ing and makes both electrodes electrically “HOT”.
DUAL CYLINDER MOUNTING KIT
(K1702-1)
Permits stable side-by-side mounting of two full size
(9" dia. x 5' high) gas cylinders with “no lift” loading.
Simple installation and easy instructions provided.
Includes upper and lower cylinder supports, wheel
axles and mounting hardware.
2. Pulling SPOOL GUN Trigger:
•
•
Disables built-in feeder gun operation.
Changes the displays of the POWER MIG 300 to
correspond to Spool Gun operation.
•
Closing spool gun trigger starts spool gun welding
and makes both electrodes electrically “HOT”.
3. Operation with POWER MIG 300:
ALTERNATIVE MAGNUM GMAW
GUN AND CABLE ASSEMBLIES
•
•
•
Install the spool gun per the installation instructions
Turn the POWER MIG 300 input power ON.
Make sure that the Gun Selector Switch is in the
“Standard / Spool Gun” position.
The following Magnum 300 gun and cable assemblies
are separately available for use with the POWER MIG
300. Each is rated 300 amps 60% duty cycle (or 300
amps 40% duty) and is equipped with the integrated
connector, twist-lock trigger connector, fixed nozzle
and insulator, and includes a liner, diffuser, and con-
tact tips for the wire sizes specified:
•
Pull and release the trigger of the Spool Gun. The
Power Mig recognizes the spool gun as active and weld
parameters are adjustable for welding with the Spool
Gun
POWER MIG 300
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C-3
C-3
ACCESSORIES
Non-Synergic Weld Modes (Mode 5)
Remember: The dialed in SPD value at the POWER
MIG 300 does not control the WFS at the spool gun.
Rather, it is adjusting the POWER MIG 300 synergic
work point. Therefore, adjusting the SPD value will
not change your actual WFS at the spool gun.
WFS can only be changed at the spool gun.
•
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 source is
inactive. Wire Feed Speed is set at the Spool
Gun.
PUSH-PULL FEEDING CONNECTION
ADAPTER KIT (K2154-1)
The push-pull adapter kit provides direct connection of
a Cobra Gold or Prince XL torch to the POWER MIG 300
wire feeder welder.
•
The following procedure settings for Aluminum
4043 can be used as initial settings for making
test welds to determine final settings:
The kit is intended for use with the following Cobra
Gold or Prince XL torches:
Wire Dia.
In. (mm)
WFS Setting
Spool Gun
Arc Voltage
Setting
Cobra Gold
.030" (.8 mm)
.035" (.9 mm)
3/64" (1.2 mm)
270
250
240
15V
16V
20V
Air Cooled 15’(5m) K1589-1 Water-Cooled 15’(5m) K1590-1
Air Cooled 25’(8m) K1589-2 Water-Cooled 25’(8m) K1590-2
Air Cooled 50’(15m) K1589-3 Water-Cooled 50’(15m) K1590-3
4. Synergic Weld Modes
Prince XL
Air Cooled 15’(5m) K1591-1 Water-Cooled 15’(5m) K1592-1
Air Cooled 25’(8m) K1591-2 Water-Cooled 25’(8m) K1592-2
Air Cooled 50’(15m) K1591-3 Water-Cooled 50’(15m) K1592-3
The POWER MIG 300 is designed to enable synergic
weld modes and synergic pulse processes with the
spool gun. The actual wire feed speed (WFS) of the
spool gun must be measured and manually set on the
POWER MIG 300 as a work point for the POWER
MIG 300 (SPD).
CAUTION
Remove all input power to the POWER MIG 300
before installing the Connection Adapter Kit.
------------------------------------------------------------------------
•
In synergic modes when the spool gun trigger is
pulled, an adjustable value for the SPD work
point is displayed in the left meter. The letters
SPD are displayed in the right meter.
WARNING
Refer to the Owner’s Manual of the Torch for
Amperage and Duty Cycle rating information. The
torch rating may not match the rating of the power
source.
------------------------------------------------------------------------
MAKING A WELD WITH THE PRINCE XL
OR COBRA GOLD TORCH INSTALLED
•
•
The left control knob adjusts the SPD value.
The right control knob is inactive.
Measure the actual WFS, in inches per minute,
at the spool gun and set the SPD at the
POWER MIG 300 to match this value. WFS can
be measured by pulling the trigger of the spool
gun and feeding wire for 6 seconds. Measure
the length of wire (in inches) that was fed and
multiply by 10.
• Set the idle roll pressure on the wire drive between
an indicator reading of 0-2. A recommended start
point is 1.5.
• Set the Gun Selection toggle switch located inside
the wire drive compartment directly above the push-
pull control cable connector to "PUSH-PULL GUN."
• Depending on the weld mode, set the Voltage or
Trim at the POWER MIG 300 using the right control
knob located on the upper case front panel.
•
•
•
The POWER MIG 300 is now configured and
ready to weld in the synergic mode.
Adjustment of the SPD value from the set value
has the affect of adjusting trim or arc length.
To increase the arc length; increase the SPD
value at the POWER MIG 300 to a value higher
than the actual WFS.
• The Wire Feed Speed (WFS) is set using the control
knob on the Torch. The left control knob on the
POWER MIG 300 is inactive. The actual WFS being set
Remember; do not change the WFS at the spool
gun.
• To decrease the arc length; decrease the SPD
value at the POWER MIG 300 to a value lower
than the actual WFS.
at the torch is displayed on the POWER MIG 300
.
• All weld parameters normally available for the active
weld mode are available during push-pull operation.
Refer to the Operation Section of this manual.
POWER MIG 300
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C-4
C-4
NOTES
POWER MIG 300
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D-1
D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance..........................................................................................................................Section D
Safety Precautions & General Maintenance ...............................................................................D-2
Liner Removal and Replacement................................................................................................D-3
POWER MIG 300
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D-2
D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
CONTACT TIP AND GAS NOZZLE
INSTALLATION
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.
ELECTRIC SHOCK can kill.
• Have an electrician install and
service this equipment.
• Turn the input power off at the
fuse box before working on
equipment
b. Be sure the nozzle insulator is fully screwed onto
the gun tube and does not block the gas holes in
the diffuser. (NOTE: Insulator is not required when
using the optional fixed gas nozzles.)
• Do not touch electrically hot
parts.
c. Slip the appropriate gas nozzle onto the nozzle
insulator. Adjustable gas nozzles are available with
a .62” (15.9 mm) or .50” (12.7 mm) I.D., and in both
standard (flush) and recessed design. The proper
nozzle should be selected based on the welding
application. Different length fixed nozzles are also
available to fit 300 and 400 amp gun tubes to allow
either spray or short-circuiting transfer welding.
GENERAL MAINTENANCE
In extremely dusty locations, dirt may clog the air pas-
sages causing the welder to run hot. Blow dirt out of
the welder with low-pressure air at regular intervals to
eliminate excessive dirt and dust build-up on internal
parts.
Choose the gas nozzle as appropriate for the
GMAW process to be used. Typically, the contact
tip end should be flush to .12” (3.1 mm) extended
for the short-circuiting transfer process and .12”
(3.1 mm) recessed for spray transfer. For the
Outershield (FCAW) process, 1/8” (3 mm) recess is
recommended.
The fan motors have sealed ball bearings which
require no service.
DRIVE ROLLS AND GUIDE PLATES
After every coil of wire, inspect the wire drive mecha-
nism. Clean it as necessary by blowing with low pres-
sure compressed air. Do not use solvents for cleaning
the idle roll because it may wash the lubricant out of
the bearing. All drive rolls are stamped with the wire
sizes they will feed. If a wire size other than that
stamped on the roll is used, the drive roll must be
changed.
GUN TUBES AND NOZZLES
a. Replace worn contact tips as required.
b. Remove spatter from inside of gas nozzle and from
tip after each 10 minutes of arc time or as required.
GUN CABLE CLEANING
For instructions on replacing or changing drive roll,
see “Wire Drive Rolls” in Operation section.
To help prevent feeding problems, clean cable liner
after using approximately 300 pounds (136 kg) of
electrode. Remove the cable from the wire feeder and
lay it out straight on the floor. Remove the contact tip
from the gun. Using an air hose and only partial pres-
sure, gently blow out the cable liner from the gas dif-
fuser end.
POWER MIG 300
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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.
CAUTION
Excessive pressure at the start may cause the dirt
to form a plug.
6. Lay the cable straight and trim Liner to 9/16”.
Remove burrs.
Flex the cable over its entire length and again blow
out the cable. Repeat this procedure until no further
dirt comes out. If this has been done and feed prob-
lems are experienced, try liner replacement, and refer
to trouble shooting section on rough wire feeding.
7. Secure the gas diffuser into the tube.
8. Tighten the set screw against the Liner.
CAUTION
LINER REMOVAL AND REPLACEMENT
(SEE FIGURE D.1)
This screw should only be gently tightened. Over
tightening will split or collapse the liner and cause
poor wire feeding.
LINER REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR MAGNUM 300
------------------------------------------------------------------------
NOTE: The variation in cable lengths prevents the
interchangeability of liners between guns. Once a liner
has been cut for a particular gun, it should not be
installed in another gun unless it can meet the liner
cutoff length requirement. Liners are shipped with the
jacket of the liner extended the proper amount.
1. Remove the gas nozzle.
2. Remove the gas diffuser from the gun tube. If gas
diffuser contains a small set screw, loosen the set
screw.
3. Lay gun and cable out straight on a flat surface.
Loosen set screw of the connector on the back end
of the gun.
4. Insert the untrimmed Liner into the back end of the
gun.
FIGURE D.1
FEEDR END
CABLE HANDLE
GUN HANDLE
GUN TUBE
INSULATION TUBE
BRASS CABLE
CONNECTOR
9/16 (14.3mm)
LINER TRIM
LENGTH
MOLDED GAS PLUG
SET SCREW
CLAMPING SCREW
SET SCREW
GAS DIFFUSER
LINER ASSEMBLY (LINER BUSHING TO BE SEATED
TIGHT AGIANST BRASS CABLE CONNECTOR)
NOZZLE INSULATION
GAS NOZZLE
POWER MIG 300
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Section E-1
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation .............................................................................................................Section E
General Description .......................................................................................................E-2
Input Voltage and Main Transformer ..............................................................................E-3
Input Rectifier, Chopper Assembly And Feedback .........................................................E-4
Diode Control Rectifier and Power Board ......................................................................E-5
Weld Control Board ........................................................................................................E-6
Wire Drive Motor and Feedback .....................................................................................E-7
Thermal Protection, Over Current Protection, and Wire Feeder
Overload Protection .................................................................................................E-8
Insulated Gate Bipolar Transistor (IGBT) Operation.......................................................E-9
Pulse Width Modulation ..........................................................................................E-10
Chopper Technology Fundamentals........................................................................E-11
FIGURE E.1 – POWER MIG 300 BLOCK LOGIC DIAGRAM
MAIN
TRANSFORMER
OUTPUT
RECTIFIER
CHOPPER
ASSEMBLY
POS
OUTPUT
TERMINAL
OUTPUT
CHOKE
GUN
+
IGBT
+
CURRENT
TRANSDUCER
80
VAC
60
VAC
_
RECONNECT
PANEL
NEG
OUTPUT
TERMINAL
CURRENT
FEEDBACK
30
VAC
POWER
BOARD
40 VDC
20 VDC
PWM
115
VAC
LINE
VOLTAGE
FEEDBACK
SWITCH
DIODE CONTROL
RECTIFIER
SIGNALS
+15/-15/+5 VDC
IGBT
DRIVE
RELAY
CHOPPER
RS232
CONNECTOR
FAN
WELD CONTROL BOARD
MOTOR
40
VDC
SEC
TO FAN RELAY
FROM WELD
CONTROL BOARD
THERMOSTATS
ARCLINK
+5 VDC
SHIELDED CABLE AND SPI COMMUNICATIONS
FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL)
SPOOL
40 VDC
DISPLAY
BOARD
ENCODER
BOARD
(Below code 10900)
SHIELDED
CABLE
MSP
BOARD
FEEDER
BOARD
24 VDC
GUN
BOARD
GUN TRIGGER AND THUMB SWITCH
SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL)
SPOOL GUN
PUSH-PULL
SWITCH
T
GAS
SOLENOID
A
C
H
Mechanical Encoders
(Above code 10900)
WIRE DRIVE
MOTOR
POWER MIG 300
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – INPUT VOLTAGE AND MAIN TRANSFORMER
MAIN
TRANSFORMER
OUTPUT
RECTIFIER
CHOPPER
ASSEMBLY
POS
OUTPUT
TERMINAL
OUTPUT
CHOKE
GUN
+
IGBT
+
CURRENT
TRANSDUCER
80
VAC
60
VAC
_
RECONNECT
PANEL
NEG
OUTPUT
TERMINAL
CURRENT
FEEDBACK
30
VAC
POWER
BOARD
40 VDC
20 VDC
PWM
115
VAC
LINE
VOLTAGE
FEEDBACK
SWITCH
DIODE CONTROL
RECTIFIER
SIGNALS
+15/-15/+5 VDC
IGBT
DRIVE
RELAY
CHOPPER
RS232
CONNECTOR
FAN
WELD CONTROL BOARD
MOTOR
40
VDC
SEC
TO FAN RELAY
FROM WELD
CONTROL BOARD
THERMOSTATS
ARCLINK
+5 VDC
SHIELDED CABLE AND SPI COMMUNICATIONS
FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL)
SPOOL
40 VDC
DISPLAY
BOARD
ENCODER
BOARD
(Below code 10900)
SHIELDED
CABLE
MSP
BOARD
FEEDER
BOARD
24 VDC
GUN
BOARD
GUN TRIGGER AND THUMB SWITCH
SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL)
SPOOL GUN
PUSH-PULL
SWITCH
T
GAS
SOLENOID
A
C
H
Mechanical Encoders
(Above code 10900)
WIRE DRIVE
MOTOR
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% duty cycle. The standard machine is equipped to
weld CC Stick, CC-GTAW, CV-FCAW, and synergic
and non-synergic CV GMAW/GMAW-P, Pulse-on-
Pulse, and Power Mode welding processes.
The digital microcomputer based control system allows
easy and accurate adjustment of weld parameters
through the multi-process panel located on the front of
the machine. The Power MIG 300 is equipped with a
6-pin connector for a foot amptrol or remotes and a 7-
pin connector to allow operation of a spool gun or a
push-pull gun for feeding aluminum wires.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER MIG 300
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – INPUT RECTIFIER, CHOPPER ASSEMBLY AND FEEDBACK
MAIN
TRANSFORMER
OUTPUT
RECTIFIER
CHOPPER
ASSEMBLY
POS
OUTPUT
TERMINAL
OUTPUT
CHOKE
GUN
+
IGBT
+
CURRENT
TRANSDUCER
80
VAC
60
VAC
_
RECONNECT
PANEL
NEG
OUTPUT
TERMINAL
CURRENT
FEEDBACK
30
VAC
POWER
BOARD
40 VDC
20 VDC
PWM
115
VAC
LINE
SWITCH
VOLTAGE
FEEDBACK
DIODE CONTROL
RECTIFIER
SIGNALS
+15/-15/+5 VDC
IGBT
DRIVE
RELAY
CHOPPER
RS232
CONNECTOR
FAN
WELD CONTROL BOARD
MOTOR
40
VDC
SEC
TO FAN RELAY
FROM WELD
CONTROL BOARD
THERMOSTATS
ARCLINK
+5 VDC
SHIELDED CABLE AND SPI COMMUNICATIONS
FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL)
40 VDC
SPOOL
GUN
BOARD
DISPLAY
BOARD
ENCODER
BOARD
(Below code 10900)
SHIELDED
CABLE
MSP
BOARD
FEEDER
BOARD
24 VDC
GUN TRIGGER AND THUMB SWITCH
SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL)
SPOOL GUN
PUSH-PULL
SWITCH
T
GAS
SOLENOID
A
C
H
Mechanical Encoders
(Above code 10900)
WIRE DRIVE
MOTOR
INPUT VOLTAGE 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 located on the rear of
the machine, allows the user to configure the Power
MIG 300 for either 230V, 460V, or 575V input supply
power. An ON/OFF line switch is located on the front
panel. When the line switch is ON, AC input voltage is
applied to the primary winding of the main transformer.
The main transformer converts the high voltage, low
current input power to a low voltage, high current out-
put. The main transformer also has two isolated auxil-
iary windings. One supplies 30 VAC to a Diode Control
Rectifier, which converts the 30 VAC to 40 VDC to sup-
ply the Power Board and the Spool Gun Board. The
Power Board in turn supplies 20
VDC to the Chopper Board and +15 VDC, -15 VDC and
+5 VDC to the Weld Control Board circuitry. The other
auxiliary winding provides 115 VAC to operate a ther-
mostatically controlled fan motor through a relay, which
also receives signals from the Weld Control Board.
The fan is designed to come on automatically when the
trigger is pulled. The fan will stay on as needed for a
minimum of six minutes after the weld arc is terminat-
ed. The fan will also stay on when the machine's weld-
ing and feeding are disabled during thermostatic over-
temperature protection. (See Thermal and Overload
Protection.)
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER MIG 300
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 – DIODE CONTROL RECTIFIER AND POWER BOARD
MAIN
TRANSFORMER
OUTPUT
RECTIFIER
CHOPPER
ASSEMBLY
POS
OUTPUT
TERMINAL
OUTPUT
CHOKE
GUN
+
IGBT
+
CURRENT
TRANSDUCER
80
VAC
60
VAC
_
RECONNECT
PANEL
NEG
OUTPUT
TERMINAL
CURRENT
FEEDBACK
30
VAC
POWER
BOARD
40 VDC
20 VDC
PWM
115
VAC
LINE
VOLTAGE
FEEDBACK
SWITCH
DIODE CONTROL
RECTIFIER
SIGNALS
+15/-15/+5 VDC
IGBT
DRIVE
RELAY
CHOPPER
RS232
CONNECTOR
FAN
MOTOR
WELD CONTROL BOARD
40
VDC
SEC
TO FAN RELAY
FROM WELD
CONTROL BOARD
THERMOSTATS
ARCLINK
+5 VDC
SHIELDED CABLE AND SPI COMMUNICATIONS
FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL)
SPOOL
40 VDC
DISPLAY
BOARD
ENCODER
BOARD
(Below code 10900)
SHIELDED
CABLE
MSP
BOARD
FEEDER
BOARD
24 VDC
GUN
BOARD
GUN TRIGGER AND THUMB SWITCH
SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL)
SPOOL GUN
PUSH-PULL
SWITCH
T
GAS
SOLENOID
A
C
H
Mechanical Encoders
(Above code 10900)
WIRE DRIVE
MOTOR
INPUT
RECTIFIER,
CHOPPER
ASSEMBLY AND FEEDBACK
The 60 VAC output from the main transformer sec-
ondary is connected to an input rectifier. The resultant
80 VDC is applied to four parallel capacitors incorpo-
rated within the Chopper Assembly. These capacitors
function as filters and also as power supplies for the
insulated gate bipolar transistors or IGBT. See IGBT
Operation in this section. The IGBT acts as a high-
speed switch operating at 20KHZ. This device is
switched on and off by the Weld Control Board through
pulse width modulation circuitry. See Pulse Width
Modulation in this section. This "chopped" DC output
is applied through an output choke coil to the positive
output terminal and through a current transducer to the
negative output terminal. The choke functions as a
current filter. A free-wheeling diode is incorporated in
the Chopper Assembly to provide a current path for the
stored energy in the choke when the IGBT is turned off.
See Chopper Technology Fundamentals in this sec-
tion.
Output voltage and current feedback information is fed
to the Weld Control Board. This information is sensed
from the current transducer and voltage sense circuitry
on the output terminal circuits. If current or voltage
become abnormally high, the Weld Control Board will
shut off the IGBTs, thus disabling the machine's output.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER MIG 300
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 – WELD CONTROL BOARD
MAIN
TRANSFORMER
OUTPUT
RECTIFIER
CHOPPER
ASSEMBLY
POS
OUTPUT
TERMINAL
OUTPUT
CHOKE
GUN
+
IGBT
+
CURRENT
TRANSDUCER
80
VAC
60
VAC
_
RECONNECT
PANEL
NEG
OUTPUT
TERMINAL
CURRENT
FEEDBACK
30
VAC
POWER
BOARD
40 VDC
20 VDC
PWM
115
VAC
LINE
VOLTAGE
FEEDBACK
SWITCH
DIODE CONTROL
RECTIFIER
SIGNALS
+15/-15/+5 VDC
IGBT
DRIVE
RELAY
CHOPPER
RS232
CONNECTOR
FAN
WELD CONTROL BOARD
MOTOR
40
VDC
SEC
TO FAN RELAY
FROM WELD
CONTROL BOARD
THERMOSTATS
ARCLINK
+5 VDC
SHIELDED CABLE AND SPI COMMUNICATIONS
FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL)
SPOOL
40 VDC
DISPLAY
BOARD
ENCODER
BOARD
(Below code 10900)
SHIELDED
CABLE
MSP
BOARD
FEEDER
BOARD
24 VDC
GUN
BOARD
GUN TRIGGER AND THUMB SWITCH
SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL)
SPOOL GUN
PUSH-PULL
SWITCH
T
GAS
SOLENOID
A
C
H
Mechanical Encoders
(Above code 10900)
WIRE DRIVE
MOTOR
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.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER MIG 300
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E-6
E-6
THEORY OF OPERATION
FIGURE E.6 – WIRE DRIVE MOTOR AND FEEDBACK
MAIN
TRANSFORMER
OUTPUT
RECTIFIER
CHOPPER
ASSEMBLY
POS
OUTPUT
TERMINAL
OUTPUT
CHOKE
GUN
+
IGBT
+
CURRENT
TRANSDUCER
80
VAC
60
VAC
_
RECONNECT
PANEL
NEG
OUTPUT
TERMINAL
CURRENT
FEEDBACK
30
VAC
POWER
BOARD
40 VDC
20 VDC
PWM
115
VAC
LINE
VOLTAGE
FEEDBACK
SWITCH
DIODE CONTROL
RECTIFIER
SIGNALS
+15/-15/+5 VDC
IGBT
DRIVE
RELAY
CHOPPER
RS232
CONNECTOR
FAN
MOTOR
WELD CONTROL BOARD
40
VDC
SEC
TO FAN RELAY
FROM WELD
CONTROL BOARD
THERMOSTATS
ARCLINK
+5 VDC
SHIELDED CABLE AND SPI COMMUNICATIONS
FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL)
SPOOL
40 VDC
DISPLAY
BOARD
ENCODER
BOARD
(Below code 10900)
SHIELDED
CABLE
MSP
BOARD
FEEDER
BOARD
24 VDC
GUN
BOARD
GUN TRIGGER AND THUMB SWITCH
SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL)
SPOOL GUN
PUSH-PULL
SWITCH
T
GAS
SOLENOID
A
C
H
Mechanical Encoders
(Above code 10900)
WIRE DRIVE
MOTOR
WELD CONTROL BOARD
In addition, the Weld Control Board monitors the
Chopper thermostat and the Main Transformer sec-
ondary winding thermostat. In the event of a fault con-
dition, the Weld Control Board will activate the thermal
light and will disable or reduce the machine output.
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 and processed at the Weld Control Board.
Software within the Weld Control Board processes the
command and feedback information and sends the
appropriate pulse width modulation (PWM) signals to
the Chopper Assembly IGBT. (See Pulse Width
Modulation in this section.) In this manner, a digitally
controlled high-speed welding waveform is created.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER MIG 300
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E-7
E-7
THEORY OF OPERATION
FIGURE E.7 – WIRE DRIVE MOTOR AND FEEDBACK
MAIN
TRANSFORMER
OUTPUT
RECTIFIER
CHOPPER
ASSEMBLY
POS
OUTPUT
TERMINAL
OUTPUT
CHOKE
GUN
+
IGBT
+
CURRENT
TRANSDUCER
80
VAC
60
VAC
_
RECONNECT
PANEL
NEG
OUTPUT
TERMINAL
CURRENT
FEEDBACK
30
VAC
POWER
BOARD
40 VDC
20 VDC
115
VAC
LINE
VOLTAGE
FEEDBACK
SWITCH
PWM
DIODE CONTROL
RECTIFIER
SIGNALS
+15/-15/+5 VDC
IGBT
DRIVE
RELAY
CHOPPER
RS232
CONNECTOR
FAN
MOTOR
WELD CONTROL BOARD
40
VDC
SEC
TO FAN RELAY
FROM WELD
CONTROL BOARD
THERMOSTATS
ARCLINK
+5 VDC
SHIELDED CABLE AND SPI COMMUNICATIONS
FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL)
SPOOL
40 VDC
DISPLAY
BOARD
ENCODER
BOARD
(Below code 10900)
SHIELDED
CABLE
MSP
BOARD
FEEDER
BOARD
24 VDC
GUN
BOARD
GUN TRIGGER AND THUMB SWITCH
SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL)
SPOOL GUN
PUSH-PULL
SWITCH
T
GAS
SOLENOID
A
C
H
Mechanical Encoders
(Above code 10900)
WIRE DRIVE
MOTOR
WIRE DRIVE MOTOR AND FEED-
BACK
The Wire Drive Motor is controlled by the Feeder Board
and the Weld Control Board. A motor speed feedback
signal is generated at the motor Tach and sent to the
Feeder Board, which compares this feedback signal to
the commands from the Encoder. It then sends the
appropriate armature voltage to the Wire Drive Motor.
This controlled wire drive speed in turn regulates the
electrode wire feed speed through the gun.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
POWER MIG 300
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E-8
E-8
THEORY OF OPERATION
THERMAL PROTECTION
OVER CURRENT PROTECTION
Two 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 Transformer.
Excessive temperatures may be caused by a lack of
cooling air or by operating the machine beyond its duty
cycle or output rating. If excessive operating tempera-
tures should occur, the thermostats will prevent output
from the machine. The yellow thermal light, located on
the front of the machine, will be illuminated. The ther-
mostats are self resetting once the machine cools suf-
ficiently. If the thermostat shutdown was caused by
excessive output or duty cycle and the fan is operating
normally, the power switch may be left on and the reset
should occur within a 15-minute period. If the fan is not
turning or the intake air louvers are obstructed, the
power must be removed from the machine and the fan
condition or air obstruction corrected. The cooling fan
runs only when necessary. The F.A.N. (fan as needed)
system is controlled by the Weld Control Board via
solid state relay.
If the average current exceeds 300 to 320 amps, the
peak current will be limited to 100 amps until the sys-
tem is re-triggered or the average current decreases to
under 50 amps.
WIRE FEEDER OVERLOAD PRO-
TECTION
The Power MIG 300 wire drive motor has its own solid
state overload protection. If the motor becomes over-
loaded, the protection circuitry turns off the wire feed
and the gas solenoid. Overload may result from
improperly sized tip liner and drive rolls, obstructions or
bends in the gun cable, and any other factors that
would impede the wire feeding. To resume welding,
simply pull the gun trigger. There is no circuit breaker
to reset, as the protection is provided by reliable solid
state electronics.
POWER MIG 300
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E-9
E-9
THEORY OF OPERATION
FIGURE E.8 – IGBT OPERATION
POSITIVE
VOLTAGE
APPLIED
GATE
GATE
SOURCE
SOURCE
n +
n +
n +
n +
p
BODY REGION
p
BODY REGION
DRAIN DRIFT REGION
DRAIN DRIFT REGION
n -
n -
n +
p +
BUFFER LAYER
n +
p +
BUFFER LAYER
INJECTING LAYER
INJECTING LAYER
DRAIN
DRAIN
B. ACTIVE
A. PASSIVE
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconduc-
tors well suited for high frequency switching and high
current applications.
Drawing B shows the IGBT in an active mode. When
the gate signal, a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it is
capable of conducting current. A voltage supply con-
nected to the drain terminal will allow the IGBT to con-
duct and supply current to circuit components coupled
to the source. Current will flow through the conducting
IGBT to downstream components as long as the posi-
tive gate signal is present. This is similar to turning ON
a light switch.
Drawing A shows an IGBT in a passive mode. There is
no gate signal, zero volts relative to the source, and
therefore, no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since
there is no conduction the circuit will not supply current
to components connected to the source. The circuit is
turned off like a light switch in the OFF position.
POWER MIG 300
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E-10
E-10
THEORY OF OPERATION
FIGURE E.9 – TYPICAL IGBT OUTPUTS
sec
48
sec
sec
sec
50
MINIMUM OUTPUT
sec
24
sec
sec
24
2
sec
50
MAXIMUM OUTPUT
PULSE WIDTH MODULATION
IGBT group conducting for 1 microsecond. The nega-
tive portion is the other IGBT group. The dwell time
(off time) is 48 microseconds (both IGBT groups off).
Since only 2 microseconds of the 50-microsecond time
period is devoted to conducting, the output power is
minimized.
The term PULSE WIDTH MODULATION 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 MODULATION.
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.
MAXIMUM OUTPUT
MINIMUM OUTPUT
By holding the gate signals on for 48 microseconds
each and allowing only 2 microseconds of dwell time
(off time) during the 50-microsecond cycle, the output is
maximized. The darkened area under the top curve
can be compared to the area under the bottom curve.
The more dark area under the curve, the more power is
present.
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during a
cycle. The top drawing below shows the minimum out-
put signal possible over a 50-microsecond time period.
The positive portion of the signal represents one
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E-11
E-11
THEORY OF OPERATION
CHOPPER TECHNOLOGY
FUNDAMENTALS
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, similar to the inverter machines. A block diagram
for this is as follows:
FIGURE E.10
SOLID STATE
SWITCH
INDUCTOR
AND DIODE
DC RECTIFIER
AND FILTER
SINGLE-PHASE
INPUT POWER
ARC
ARC
CONTROL
+
ARC
80VDC
DIODE
CURRENT WITH SWITCH OPEN
_
INDUCTOR
SWITCH
CURRENT WITH SWITCH CLOSED
In this system, the engine drives a three-phase alternator, which generates power that is rectified and filtered to
produce about 80VDC. The current is applied through a solid state switch to an inductor. By turning the switch
on and off, current in the inductor and the arc can be controlled. The above diagram depicts the current flow in
the system when the switch is open and closed:
When the switch is closed, current is applied through the inductor to the arc. When the switch opens, current
stored in the inductor sustains flow in the arc and through the diode. The repetition rate of switch closure is 20Khz,
which allows ultra-fast control of the arc. By varying the ratio of on time versus off time of the switch (Duty Cycle),
the current applied to the arc is controlled. This is the basis for Chopper Technology: Controlling the switch in such
a way as to produce superior welding.
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Section F-1
Section F-1
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Troubleshooting & Repair Section ................................................................................Section F
How to Use Troubleshooting Guide.......................................................................................F-2
PC Board Troubleshooting Procedures .................................................................................F-3
Troubleshooting Guide ................................................................................................F-4 - F-11
Chopper Board Capacitor Discharge Procedure ..........................................................F-12
Main Transformer Test ..................................................................................................F-14
Chopper Board Test ......................................................................................................F-16
Control Rectifier Test .....................................................................................................F-19
Output Rectifier Assembly Test ....................................................................................F-21
Wire Drive Motor and Tachometer Feedback Test .......................................................F-23
Encoder PC Board Test (10562 & Above).....................................................................F-26
Current Transducer Test................................................................................................F-29
Power Mig Scrolling Dashes Test..................................................................................F-32
Oscilloscope Waveforms......................................................................................................F-34
Removal and Replacement Procedures..............................................................................F-36
Motor & Gear Box Removal and Replacement.............................................................F-36
Output Rectifier Removal and Replacement.................................................................F-40
Chopper Board Assembly Removal and Replacement.................................................F-43
Main Transformer and Output Choke Removal and Replacement ...............................F-46
Fan Motor Assembly Removal and Replacement.........................................................F-50
Voltage & Current Calibration Procedure......................................................................F-52
Retest after Repair...............................................................................................................F-57
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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 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 malfunc-
tions. Simply follow the three-step procedure list-
ed below.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the sub-
ject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM” (SYMP-
TOMS). This column describes possible symp-
toms that the machine may exhibit. Find the list-
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into four main categories: Output Problems,
Function Problems, Wire Feeding, and Welding
Problems.
All of the referenced test procedures referred to in
the Troubleshooting Guide are described in detail
at the end of this section.
Refer to the
Troubleshooting and Repair Table of Contents
to locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced elec-
trical wiring diagrams and schematics. Refer to
the Machine Schematic and Electrical
Diagrams Section Table of Contents to locate the
appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be con-
ducted without removing the case cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 1-800-833-9353.
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield-
ing bag.
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
- Remove your body’s static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
grounded part of the
equipment frame.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
Workstations
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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F-4
F-4
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local Lincoln 1. Contact the Lincoln Electric
is evident.
Authorized
Facility.
Field
Service
Service Department at 1-800-
833-9353 (WELD).
Machine is dead - no welding out-
put and no wire feed when gun
trigger is pulled.
1. Make certain that the input power 1. Check for the correct input volt-
switch is in the "ON" position.
age at the line switch. (L1-L2)
See Wiring Diagram.
2. Check the input voltage at the
machine. Input voltage must 2. Check for loose or faulty con-
match the rating plate and the
reconnect panel.
nections between the line
switch and the reconnect panel.
3. Blown or missing fuses in the 3. Perform the Main Transformer
input line. Test.
4. Check for thermal light on case 4. Check the red LED’s (1 & 2) on
front. Thermostats may be open
due to machine overheating. If
machine operates normally after
a cooling off period then check
for proper fan operation and ven-
tilation. Make certain that the
machine’s duty cycle is not being
exceeded.
the digital power supply board.
They should be lit indicating
that DC voltage is being applied
to plugs J42 and J43. See
Wiring Diagram.
If LED’s 1 & 2 are not lit check
for the presence of 42 VDC at
plug J41 pin 2(+) and pin 1(-). If
the 42 VDC is present and
LED’s 1 & 2 are not lit the digital
power supply board may be
faulty.
5. Remove the gun trigger connec-
tion and jump the two connec-
tions at the machine. If you
have a wirefeed gun, it may be
faulty. Replace.
If the 42 VDC is not present at
plug J41 perform the Control
Rectifier Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
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F-5
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
No welding output but wire feeds 1. Check the input voltage at the 1. Check for loose or broken con-
normally when gun trigger is pulled.
machine. Input voltage must
match the rating plate and the
reconnect panel.
nections at the output terminals,
the choke and all heavy current
carrying leads. See the Machine
Schematic.
2. The gun may be faulty. Check for
continuity.
2. Make sure that the transformer
secondary leads are securely
connected to the Output Rectifier
assembly.
3. Check continuity through the
work lead.
3. Check for OCV at output studs
when trigger is pulled. If OCV is
present, the gun may be faulty.
Replace.
4. Check for 57VAC at the input of
output rectifier. If reading is not
correct
Perform
Main
Transformer Tests. If you mea-
sure approximately 57 VAC,
check for 80VDC at the output of
the output rectifier. If reading is
not correct perform the Output
Rectifier Assembly Tests. If
80VDC is there Perform
Chopper Board Test.
5. Check for 15VDC input to the
Control Board at leads 12J4
(412) to 10J4 (410), -15VDC at
leads 11J4 (411) to 10J4 (410),
5VDC at leads 8J4 (408) to 10J4
(410). If missing a voltage check
wiring back to Digital Power
Supply PCB. If voltage is ok, the
Control Board may be faulty.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
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F-6
F-6
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
OUTPUT PROBLEMS
Wire feeds but welding output is 1. Make sure that the proper wire 1. Check for loose or faulty con-
low causing wire to “stub”. Welds
are “cold”. Machine cannot obtain
full rated output of 300 amps at 32 2. Check gun and work cable for
volts. loose or faulty connections.
and procedures are being used.
nections of the heavy current
carrying leads.
Diagram
See Wiring
2. Perform
the
Current
Transducer Test.
3. Perform Output Waveform
Test.
4. Perform the Output Rectifier
Assembly Tests
5. The Control Board may be faulty.
Replace.
The output voltage and wire feed is 1. Remove the gun. If the problem 1. Find J85 on Feed Head Board
present continuously or pulsing
when gun trigger is NOT activated.
is resolved, the gun trigger cir-
cuit is faulty. Repair or replace.
and unplug. If the problem still
exist Feed Head Board may be
faulty.
2. If problem persists when gun
assembly is removed from
machine, then the problem is
within the POWER MIG 300.
The output voltage is present con-
tinuously when gun trigger is NOT
activated. The wire is not feeding.
1. Find J6 on Control PCB and
unplug. If output voltage is not
present change Control PCB
2. Perform the Chopper Board
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
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F-7
F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
No control of arc voltage. Wire 1. The arc voltage encoder may be 1. The arc voltage encoder may be
feeding is normal.
dirty. Rotate several times and
check if problem is resolved.
faulty. Codes 10562 have both
Encoders on one board. Codes
above 10562 have single
Encoders.
2. If machine has code 10562 or
lower change Encoder Board. If
machine has Code above 10562
Perform Encoder Test.
3. Perform the Chopper Board
Test.
4. The Control board may be faulty.
Replace.
There is no gas flow when gun trig- 1. Check gas source and hoses for 1. Check for 6.5 VDC when trigger
ger is pulled. Wire feeds and weld
voltage is present.
leaks or kinks.
is pulled at feedhead Board, Plug
J83-3 lead 833 and J83-4 lead
834. See Wiring Diagram.
2. Check regulator on the tank for
the pressure being set to high.
If you read 12 VDC solenoid may
be open or a bad connection.
Check wiring.
Check the gas solenoid by discon-
necting it from the Feeder Board
(Plug J83-3 & 4) and applying a 12
VDC external supply to the gas
solenoid. If the solenoid does NOT
activate then it may be faulty.
Replace.
2. If 6.5VDc is not present the
Feeder broad may be faulty.
Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
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F-8
F-8
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
WIRE FEEDING PROBLEMS
No control of wire feed speed. 1. The wire feed speed encoder 1. Perform the Wire Drive Motor
Other machine functions are nor-
mal.
control may be dirty. Rotate sev-
eral times and check if problem
is resolved.
and Tachometer Feedback
Test.
2. The Wire Speed Encoder may
be faulty. If code is 10562 or
below change Encoder PCB. If
code is above 10562 Perform
Encoder Test
3. The Feeder Head Board may be
faulty. Replace.
There is no wire feed when gun 1. Check for wire jam at drive rolls. 1. Perform the Wire Drive Motor
trigger is pulled. Normal open cir-
cuit voltage is present.
and Tachometer Feedback
Test.
2. If the drive rolls are turning then
check for a mechanical restric-
tion in the wire feed path.
2. The Wire Speed Control
Encoder may be faulty. If code is
10562 and below change
Encoder PCB. If code is above
10562 Perform Encoder Test
3. The gun liner may be clogged.
Check or replace.
3. The Feeder Head Board may be
faulty. Replace.
The machine stops feeding wire 1. Check for adequate wire supply. 1. Check the motor armature cur-
while welding.
rent. Normal armature current is
2.0 to 2.7 amps maximum. If the
motor armature current is normal
the Feeder Board may be faulty.
Replace.
2. Check for mechanical restric-
tions in the wire feeding path.
The gun may be clogged.
3. Make sure the gun liner and tip
are correct for wire size being 2. If the motor armature current is
used.
high (over 2.7 amps) and there
are NO restrictions in the wire
feeding path then the motor or
gear box may be defective.
Replace.
4. Check spindle for ease of rota-
tion.
5. Check to see if the spot timer
has been activated.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
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F-9
F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The arc is unstable and or “hunt- 1. Check for worn or melted contact 1. Check for loose connections at
ing.”
tip.
the output terminals, the chokes,
and all heavy current carrying
2. Check for loose or faulty connec-
tions on the work and electrode
cables.
leads.
Diagram.
See
the
Machine
2. Make sure that the transformer
secondary leads are securely
connected to the Output Rectifier
assembly.
3. Make sure electrode polarity or
welding process being used is
correct.
4. Check for rusty or dirty wire.
3. Check the Output Voltage
Waveforms. If waveforms are
not correct Perform the Output
Rectifier Assembly Tests.
5. Make sure machine settings are
correct for process being used.
(shielding gas, wire type, wire
size).
4. Reload latest software. Contact
a Lincoln Electric sales repre-
sentative for latest software.
5. The Control board may be faulty.
Replace.
Weld bead is narrow or ropy. May 1. Make sure the weld procedure 1. Check the Output Voltage
have porosity with electrode stub-
bing into plate.
and electrode polarity is correct
for the process being used.
Welding voltage may be too low
for wire feed speed being used.
Waveforms. If waveforms are
not correct Perform the Output
Rectifier Assembly Tests.
2. Reload latest software. Contact
a Lincoln Electric sales repre-
sentative for latest software.
2. Make sure shielding gas is cor-
rect and flow is proper.
3. Make sure the weld joint is not 3. The Control board may be faulty.
“contaminated”. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
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F-10
F-10
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
POSSIBLE AREAS OF
RECOMMENDED
(SYMPTOMS)
MISADJUSTMENT(S)
COURSE OF ACTION
WELDING PROBLEMS
The contact tip seizes in the gas dif- 1. The tip being over heated due to 1. Check the Output Voltage
fuser.
excessive current and/or high
duty cycle welding.
Waveforms.
2. A light application of high temper-
ature anti-seize lubricant (such as
Lincoln E2607 Graphite Grease)
may be applied to the contact tip
threads.
The welding arc is variable and 1. Check the welding cable connec- 1. Check the OCV and Output
sluggish.
tions for loose or faulty connec-
tions.
Voltage Waverforms. If wave-
forms are not correct Perform the
Output Rectifier Assembly
Tests.
2. Make sure the wire feed speed,
voltage, and shielding gas are
correct for the process being 2. Reload latest software from a
used.
Lincoln Electric sales representa-
tive
3. The Control Board may be faulty.
Replace.
The arc striking is poor.
1. Check the welding cable connec- 1. Check the Output Voltage
tions for loose or faulty connec-
tions.
Waveforms. If waveforms are
not correct Perform the Output
Rectifier Assembly Tests.
2. Make sure the wire feed speed,
voltage, and shielding gas are 2. Reload latest software from a
correct for the process being
used.
Lincoln Electric sales representa-
tive
3. Run in settings may need to be 3. The Control board may be faulty.
adjusted. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
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F-11
F-11
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
FAULT CODES
SERVICE FACILITY
CORRECTIVE ACTION
DESCRIPTION /
DEFINITION
CORRECTIVE
ACTION
WELDING PROBLEMS
Glitch on the primary over Check the machine
Check input cord for cuts
or marks. Check input
cord connections at
reconnect panel.
39
44
current fault interrupt;
possibly caused by noise
or a signal level.
ground. Check for cuts
or marks on input cord.
Main CPU problem. The
Check the machine
Check input cord for cuts
or marks. Check input
cord connections at
DSP has detected a prob- ground. Check for cuts
lem with the CPU.
or marks on input cord.
reconnect panel. If still
bad replace Control PCB.
47
81
Glitch on the CAP/heart
beat interrupt; possibly
caused by noise or a sig-
nal level right at the trip
threshold.
Turn machine off and let
sit for 60 second and then If still bad replace Control
turn back on .
Run Scrolling dash Test.
PCB.
Motor overload-average
motor current exceeded
8.00 amps for more than
0.50 seconds.
Verify motor armature is
not binding. Verify wire
spool is not binding.
Check current at drive
motor exceeds 8 amps
change drive motor. If
under 8 amps for 0.50
seconds change Feeder
Board.
82
Motor over current-aver-
age motor current
exceeded 3.50 amps for
more than 10.0 seconds.
Verify motor armature is
not binding. Verify wire
spool is not binding.
Check current at drive
motor exceeds 3.50amps
for 10.0 seconds change
drive motor.
214
Feed Head Board can’t
be found.
Turn the machine off and
back on to reset the
Using machine schematic
Check LED 8 on Control
machine. If condition per- Bd. If not on, check for
sists, contact and autho-
rized Lincoln Field
Service Facility.
+5VDC at leads 1103 &
1104. If LED 8 is on
check for 42VDC at Feed
Head Bd. If there, Feed
Head Bd. may be faulty.
7135
7138
MSP can’t be found.
Turn the machine off and
back on to reset the
machine.
Check for bad connec-
tions at MSP panel.
The MSP panel may be
faulty. Replace.
Check for bad connec-
tions at Display Board.
The Display Board may
be faulty. Replace.
Display Board can’t be
found.
Turn the machine off and
back on to reset the
machine.
---------
Scrolling dashes
Perform Clear all test.
Perform Clear all test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353.
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F-12
F-12
TROUBLESHOOTING & REPAIR
CHOPPER BOARD CAPACITOR DISCHARGE PROCEDURE
WARNING
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 precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will insure that the five large capacitors on the Chopper Board have been
discharged. This procedure should be performed whenever work is to be attempted on or
near the Chopper Board.
MATERIALS NEEDED
3/8 in. Nutdriver
Volt/Ohmmeter
Resistor (25 ohms and 25 watts minimum)
Jumper leads
Wiring Diagram
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F-13
F-13
TROUBLESHOOTING & REPAIR
CHOPPER BOARD CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE F.1 – CHOPPER BOARD CAPACITOR TERMINAL DISCHARGE
300 CHOPPER
_
B1
B4
C11
C8
+
+
+
+
B1
B4
C2
_
B2
B5
_
B2
B5
B6
C10
C9
+
C12
_
B3
B6
B3
J99
5. Using the resistor and jumper leads, CAREFULLY
discharge the capacitor terminals. There are 5
capacitors. NEVER USE A SHORTING STRAP
FOR THIS PURPOSE. DO NOT TOUCH THE
TERMINALS WITH YOUR BARE HANDS.
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
To discharge the capacitors, hold the jumper leads to
the following terminals for a minimum of 10 seconds
each. See Figure F.1 and the Wiring Diagram.
High voltage is present when input power is applied to
the machine.
Refer to Figure F.1.
Capacitors
Terminals
1. Remove main input power supply to the machine.
2. Lift the hinged right side case cover.
C10 and C11
B1 and B2
C5
B1 and B5
B4 and B5
3. Using the 3/8 in. nutdriver, remove the bottom right
case cover.
C8 and C9
4. Locate the Chopper Board with capacitors mount-
ed on the center of the machine base, right side.
See Figure F.1.
6. Using the volt/ohmmeter, check the voltage across
terminals B1 and B2 and B1 and B5 and B4 and
B5. Each reading should now be zero volts.
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F-14
F-14
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST
WARNING
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 precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the correct voltages are being applied to the primary windings
of the main transformer and induced on the secondary and auxiliary windings.
MATERIALS NEEDED
3/8 in. Nutdriver
5/16 in. Nutdriver
Volt/Ohmmeter
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F-15
F-15
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST (continued)
FIGURE F.2 – MAIN TRANSFORMER TEST POINT LOCATIONS
LOCATED ON FRONT
OF MACHINE'S BASE
MAIN
TRANSFORMER
H1
LOCATED ON
MACHINE'S BASE
(STORAGE
H5 H2 H3 H4
H1
COMPARTMENT SIDE)
(SHOWN
CONNECTED
FOR 230V)
L1
L2
OUTPUT
LOCATED NEXT TO
MAIN TRANSFORMER
(ON WIRE DRIVE SIDE)
RECTIFIER
H2
L1
L2
LINE
SWITCH
X1
57 VAC
X2
H5
H3
RECONNECT PANEL
H4
2520
H1
s
s
m
t
t
h
a
80 VDC
o
R1
w
0
W
B
H1
H1
0
0
5
5
2400/100
-
2530
H4
G
H4
115 VAC 30 VAC
LOCATED ON
CHOPPER BOARD
ASSEMBLY
X5 X6
X3 X4
CONTROL RECTIFIER
LOCATED ON
TRANSFORMER
BAFFLE
-
5. Test for correct input voltage between L1 lead at the
LINE SWITCH to L2. Voltage tested will vary
depending on the input voltage connection. See
Wiring diagram for test point locations.
PROCEDURE
WARNING
The ON/OFF POWER SWITCH will be "hot" during
these tests.
* If the voltage is incorrect, check for loose or broken
leads between the reconnect panel and the ON/OFF
POWER SWITCH. Also, test the ON/OFF POWER
SWITCH for proper operation.
NOTE: Secondary voltages will vary proportionately
with the primary input voltage.
* If the voltage is correct, check for the same voltage
at H1 and H4 and at the bottom of the LINE
SWITCH with the switch in the ON position.
1. Disconnect the main input power supply to the
machine.
2. Perform the Case Cover Removal procedure.
* If the voltage is incorrect, check for loose or broken
leads between the reconnect panel and the LINE
SWITCH.
3. Remove the tool tray with a 5/16 in. nut-driver (3
screws).
* If the correct voltage is being applied to the main
transformer primary winding, proceed to the table
below for the secondary winding output voltage
tests.
TEST INPUT VOLTAGE TO THE MAIN TRANS-
FORMER PRIMARY WINDING:
Leads
X1-X2
X3-X4
Description
Expected Voltage
57 VAC
4. Confirm the reconnect panel is connected properly
for the correct voltage. See reconnect panel con-
nection diagram located on back of machine above
reconnect door.
Power to output
rectifier
Power to fan motor
115 VAC
Power to control
rectifier
X5-X6
30 VAC
If the correct voltage is being applied to the main
transformer and one or more of the secondary volt-
ages is missing or incorrect, the main transformer
may be faulty. Replace the main transformer.
POWER MIG 300
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F-16
F-16
TROUBLESHOOTING & REPAIR
CHOPPER BOARD TEST
WARNING
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 precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will help determine if the power module IGBT on the Chopper Board is shorted.
This test will also check for input voltage and if the PWM signal is present to activate the
IGBT. It will also determine if the Chopper Board is receiving the correct input voltages.
MATERIALS NEEDED
Volt/Ohmmeter (Analog)
3/8" Socket wrench and 6” extension
7/16" Nut driver
POWER MIG 300
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F-17
F-17
TROUBLESHOOTING & REPAIR
CHOPPER BOARD TEST (continued)
TEST PROCEDURE
EXPECTED
VOLTAGE
TO
LEAD
FROM
LEAD
1. Disconnect the main AC input power to the
machine.
437+(1J99)
431-(4J99)
20VDC
2. Remove the case side panels with a 3/8 in. nutdriv-
er.
If 20 VDC is not present check Digital Power Supply.
See the Wiring Diagram.
3. Locate plug J99. (Later machine do not have J99).
4. Make the following voltage test. From the table
below.
RESISTANCE TEST
1. Perform the Capacitor Discharge Procedure.
5. Turn the machine off between each test:
2. Remove input power to the machine.
a. Carefully insert the meter probes into the back of
each Molex plug cavity.
3. Perform the resistance tests in Table F.1.
TABLE F.1– CHOPPER BOARD RESISTANCE TEST TABLE
Test Point
B5(+)
B6(+)
B4(+)
B5(+)
B4(+)
B6(+)
B2(+)
B3(+)
B4(+)
B2(+)
B4(+)
B3(+)
Test Point
Expected Reading
6 K ohms - 9K ohms
6 K ohms - 9K ohms
200 K ohms or Higher
400 K ohms or Higher
200 K ohms or Higher
400 K ohms or Higher
6 K ohms - 9K ohms
6 K ohms - 9K ohms
200 K ohms or Higher
400 K ohms or Higher
200 K ohms or Higher
400 K ohms or Higher
B6(-)
B5(-)
B5(-)
B4(-)
B6(-)
B4(-)
B3(-)
B2(-)
B2(-)
B4(-)
B3(-)
B4(-)
FIGURE F.3 – CHOPPER BOARD CONNECTIONS
300 CHOPPER
_
B1
B4
C11
C8
+
+
+
+
B1
B4
C2
_
B2
B5
_
B2
B5
B6
C10
C9
+
C12
_
B3
B6
B3
J99
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F-18
F-18
TROUBLESHOOTING & REPAIR
CHOPPER BOARD TEST (continued)
FIGURE F.4
J6
J6
607
615
L11088-1
PWM SIGNAL TEST
1. Locate 607 (7J6) and 615 (15J6) on the control
board. See Figure F.4.
2. Perform the following voltage test or hertz read-
ings when the trigger is pulled.
Expected Voltage
To Lead
From Lead
607
(7J6)
615
(15J6)
1.8-2 VDC
20 KHZ
POWER MIG 300
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F-19
F-19
TROUBLESHOOTING & REPAIR
CONTROL RECTIFIER TEST
WARNING
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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will determine if the correct AC voltages are being applied to the Rectifier Diode
Bridge and supplied from the Rectifier Diode Bridge to the Digital Power Supply board.
MATERIALS NEEDED
Volt/Ohmmeter
3/8" Nut driver
POWER MIG 300 Machine Schematic
POWER MIG 300
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F-20
F-20
TROUBLESHOOTING & REPAIR
CONTROL RECTIFIER TEST (continued)
FIGURE F.5
115 VAC 30 VAC
X5 X6
X3 X4
CONTROL RECTIFIER
LOCATED ON
TRANSFORMER
-
FAN
BAFFLE
+ 42VDC
+
6800/75
2. Carefully connect the meter probes to the exposed
lead connections.
TEST PROCEDURE
1. Find the following leads at the control rectifier using
figures F.5 and F.6.
3. Turn the machine ON to conduct the voltage test.
Expected Voltage
From Lead
471B
To Lead
472B
X6
42 VDC
30 VAC
4. If the DC voltage tested is incorrect or missing, and
the AC voltages are correct, the control rectifier
bridge or capacitor may be faulty.
X5
FIGURE F.6
CONTROL RECTIFIER
POWER MIG 300
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F-21
F-21
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER ASSEMBLY TEST
WARNING
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 precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the Output Rectifier is shorted. See the Oscilloscope
Waveforms section of this manual for normal and abnormal output waveforms.
MATERIALS NEEDED
Analog Volt/Ohmmeter (If Digital Meter is used you must use in diode check mode.
Do not use ohms scale)
3/8” Nutdriver
5/16” Nutdriver
1/2” Wrench
Power MIG 300 Wiring Diagram (See the Machine Schematic in this manual)
POWER MIG 300
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F-22
F-22
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER ASSEMBLY TEST (continued)
FIGURE F.7– OUTPUT RECTIFIER ASSEMBLY LOCATION
+
-
Negative Lead
A A
B B
TEST PROCEDURE
5. If any of the diodes are leaky or shorted the output
rectifier assembly should be replaced.
1. Disconnect the main AC input power to the
machine.
6. When the test is complete, replace the negative out-
put previously removed.
2. Perform the Chopper Assembly Capacitor
Discharge procedure.
7. Replace case side.
3. Locate and disconnect the negative lead from the
output rectifier bridge assembly.
NOTE: Do not disassemble the rectifier assembly.
4. Test for shorted or leaky diodes by checking from
the outside plate (A) to inside plate (A) then reverse
your leads and recheck the same plates. Do the
same to plate B. The readings should be high resis-
tance in one polarity and low resistance in the oppo-
site polarity. See Figure F.7.
POWER MIG 300
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F-23
F-23
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK
TEST
WARNING
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 precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
TEST DESCRIPTION
This test will determine if the wire drive motor and voltage feedback circuits are function-
ing properly.
MATERIALS NEEDED
5/16" Nutdriver
Volt/Ohmmeter
POWER MIG 300
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F-24
F-24
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)
FIGURE F. 8 – PLUG J83 AND J84 LOCATIONS ON FEEDER BOARD
TOROID
MOTOR +
1
2
1J83
2J83
3J83
4J83
831
832
833
834
MOTOR -
GAS SOLENOID+
GAS SOLENOID -
G3884
PWM CONTROLLED
6.5 VDCWHENGAS
FLOWING COIL
LOCATED ON
CASE BACK
MEASURES 21 OHMS
12 VDC COIL
B
W
ACCESS THIS CONNECTOR
BY REMOVINGTHEWIRE
DRIVE ASSEMBLY
TOROID
MOTOR / GEARBOX
TACH
5VDC TACH SUPPLY
2.6 VDC@ 50 IN/MIN
R
U
B
R
U
B
1
841
847
844
1J84
7J84
4J84
TACH SIGNAL
TACHCOM
27.4 VDC@ 700 IN/MIN
8 SECOND AVERAGE CURRENT
LIMIT = 3.5A
2
J83
J84
3
4
MEASURE B TO U
120 Hz @ 50 IN/MIN
(LIMIT IS SOFTWARE SET)
1.6 kHz@700 IN/MIN
J84
J83
844
841
847
832
831
5. Connect the main power to the machine.
TEST PROCEDURE
NOTE: POLARITY MUST BE OBSERVED FOR
7. Make the following voltage tests. From the table
below.
THESE TESTS.
TEST FOR CORRECT WIRE DRIVE MOTOR
ARMATURE VOLTAGE
8. Carefully insert the meter probes into the back of
each Molex plug pin cavity to perform the test.
1. Disconnect main input power to the machine.
9. Turn the machine ON and pull the gun trigger to
conduct this voltage test.
2. Open the side panels and remove the tool tray
using a 5/16 in. nutdriver.
3. Locate the following leads on plug J83:
4. Locate leads 831(black) and 832(white) on plug
J83.
FROM LEAD TO LEAD EXPECTED VOLTAGE
831 +
832 -
2.5-27 VDC
(1J83)
(2J83)
(varies depending
on wire feed speed)
POWER MIG 300
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F-25
F-25
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)
TEST FOR SUPPLY VOLTAGE TO
TACHOMETER AND FEEDBACK VOLTAGE
FROM LEAD TO LEAD EXPECTED VOLTAGE
847 +
(7J84)
844 -
(4J84)
1. Locate the following leads on Plug J84. Leads 841
(1J84) and 844 (4J84)
1.5 to 3.5 VDC
2. Make the following voltage tests. From the table
below.
10. If the 1.5 to 3.5 VDC is not present or not correct,
the Feeder Board is not receiving the proper feed-
back voltage from the tachometer circuit. Check the
leads from the tachometer circuit to the Feeder
Board for loose or broken connections.
3. Turn the machine OFF between each test.
4. Carefully insert the meter probes into the back of
each Molex plug pin cavity. This is the tach supply
voltage.
11. If the leads are okay, the tachometer circuit may be
faulty, replace the tach Sensor.
FROM LEAD TO LEAD EXPECTED VOLTAGE
841 +
844 -
5 VDC
(1J84)
(4J84)
5. If the 5 VDC is present, go to next step. If no volt-
age is measured Feeder Head Board may be bad.
Check connections back to Feed Head Board.
6. Locate the leads on Plug J84 noted in the table
below.
7. Carefully insert the meter probes into the back of
each Molex plug pin cavity
8. Turn the machine ON and pull the gun trigger to
conduct the voltage test.
9. If the 1.5 to 3.5 VDC is present, the tachometer
circuit is sending the correct feedback signal to the
Feeder Board. Replace the Feeder Board.
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F-26
F-26
TROUBLESHOOTING & REPAIR
ENCODER PC BOARD TEST
(FOR CODES ABOVE 10562)
WARNING
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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the encoders are functioning properly for machines above code
10562 only.
MATERIALS NEEDED
Volt/Ohmmeter (analog recommended)
5/16" Nut driver
POWER MIG 300
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F-27
F-27
TROUBLESHOOTING & REPAIR
ENCODER PC BOARD TEST (continued)
FIGURE F. 9 - FEEDHEAD P.C. BOARD
G3884
J82
3243
J85
TEST PROCEDURE
1. Disconnect the main AC input power to the
machine.
5. Turn the machine OFF between each test.
6. Carefully insert the meter probes into the back of
each Molex plug pin cavity.
2. Locate the following leads on Plug J85 and J86
located on the feedhead P.C. Board. See Figure
F.9.
7. As you turn the encoder slowly the voltage will
change from zero to15 volts to zero, to 15 volts etc.
as you continue to turn the encoder.
3. Connect main input power to the machine.
4. Make the following voltage tests. From the tables
on following page.
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F-28
F-28
TROUBLESHOOTING & REPAIR
ENCODER PC BOARD TEST (continued)
VOLT/TRIM ENCODER #1
FROM LEAD TO LEAD EXPECTED VOLTAGE
ACTION
If you do not read 15VDC on the first reading of encoder
#1 or #2 then check lead connections. If lead connec-
tions check OK, then Feeder Board may be faulty,
replace Feeder Board.
855
5J85
3243
3J82
15 VDC
8511
11J85
3243
3J82
0 OR 15 VDC
0 OR 15 VDC
As you turn the encoder #1 or #2 slowly you should see
your meter go from 0 to 15, 0 to 15 as you turn the
encoder. If not, check the lead connections. If the lead
connection check OK then, change the encoder.
858
8J85
3243
3J82
WMF/AMPS ENCODER #2
FROM LEAD TO LEAD EXPECTED VOLTAGE
ACTION
If you do not read 15VDC on the first reading of encoder
#1 or #2 then check lead connections. If lead connec-
tions check OK, then Feeder Board may be faulty,
replace Feeder Board.
859
9J85
3243
3J82
15 VDC
857
7J85
3243
3J82
0 OR 15 VDC
As you turn the encoder #1 or #2 slowly you should see
your meter go from 0 to 15, 0 to 15 as you turn the
encoder. If not, check the lead connections. If the lead
connection check OK then, change the encoder.
POWER MIG 300
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F-29
F-29
TROUBLESHOOTING & REPAIR
CURRENT TRANSDUCER TEST
WARNING
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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will determine if the current transducer and associated wiring are functioning cor-
rectly.
MATERIALS NEEDED
Volt/Ohmmeter
3/8" Nut driver
POWER MIG 300
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F-30
F-30
TROUBLESHOOTING & REPAIR
CURRENT TRANSDUCER TEST (continued)
FIGURE F.10
J8
L11088-1
8. If excepted voltages are not present the Control
Board may be faulty.
TEST PROCEDURE
1. Remove input power to the machine
9. Check the feedback voltage from the current
transducer with the Power Mig set on Mode 1 or 2
and the machine loaded to 250 amps.
2. Remove the left case side of the machine.
3. Remove the PC compartment door.
10. Make the following voltage test. From the table
below.
4. Locate plug J8 at the Control Board. See Figure
F.10.
11. If the measured feedback voltage is not correct for
the output load current. The current transducer
may be faulty.
5. Connect the main power to the machine.
6. Make the following voltage test. From the table
FROM LEAD TO LEAD EXPECTED VOLTAGE
below. Also see Table F.2.
801
806
2.0 VDC
(1J8)
(6J8)
7. Carefully insert the meter probes into the back of
each Molex plug pin cavity.
12. If for any reason the machine cannot be loaded to
250 amps, Table F.2 shows what feedback volt-
age is produced at various current loads.
FROM LEAD TO LEAD EXPECTED VOLTAGE
802+
(2J8)
806-
(6J8)
+15 VDC
POWER MIG 300
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F-31
F-31
TROUBLESHOOTING & REPAIR
CURRENT TRANSDUCER TEST (continued)
TABLE F.2 – CURRENT TRANSDUCER FEEDBACK VOLTAGE
EXPECTED TRANSDUCER
OUTPUT LOAD CURRENT
FEEDBACK VOLTAGE
500
450
400
350
300
250
200
150
100
4.0
3.6
3.2
2.8
2.4
2.0
1.6
1.2
0.8
POWER MIG 300
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F-32
F-32
TROUBLESHOOTING & REPAIR
POWER MIG 300 SCROLLING DASHES TEST
WARNING
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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
ERROR CODE: Scrolling dashes on the POWER MIG 300 perform the appropriate clear all
procedure as follows.
MATERIALS NEEDED
None
POWER MIG 300
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F-33
F-33
TROUBLESHOOTING & REPAIR
POWER MIG 300 SCROLLING DASHES TEST (continued)
TEST PROCEDURES:
For Machines with code 10562.
For Machines with code 10952, 10958
and 11000.
1. Hold “select” switch up while powering up
machine.
1. Hold “select” switch up while powering up
machine.
2. Continue to hold “select” switch up and turn
right “encoder” until display reads “CLrAll”.
2. Release “select” switch when displays show
“PrESSPin”.
3. Release the “select” switch.
4. Machine will reset itself.
3. Turn the right “encoder knob” until displays
show “CLrAll”.
4. Toggle the “select” switch up and release.
5. Machine will reset itself.
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F-34
F-34
TROUBLESHOOTING & REPAIR
OSCILLOSCOPE WAVEFORMS MUST BE TAKEN IN MODE 201
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
2.0 MS/DIV
This is a typical DC output voltage waveform generated from a properly operating machine. Note that
20.0 V
each vertical division represents 20 volts and that each horizontal division represents 2.00 milliseconds in
time.
NOTE: Scope probes connected at the machine output terminals: (+) probe to electrode, (-) probe to work.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep..2.5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
CODES 10562 AND BELOW
CODES 10952 AND UP
Power Mig 300 in mode 201. Mode 201 is a con-
stant current test mode.
Power Mig 300 in mode 201. Mode 201 is a con-
stant current test mode.
1. Toggle and hold the Mode Select switch in the up
position.
1. Toggle and hold the Mode Select switch in the up
position.
2. Turn on the Power Mig 300.
2. Turn on the Power Mig 300.
3. Rotate the right output knob, while still holding the
Mode Select switch up, until the display reads
“ALL nodE”.
3. Once the display reads “Pres Spin” release the
mode select switch. Rotate the output knob until
the display reads “ALL nodE”.
4. Release the Mode Select switch and toggle the
Mode Set switch until the MSPlll panel reads 201.
Disengage the idler arm on the wire drive so no
wire will feed.
4. Toggle the Mode Select switch once and wait for
the machine to reset, then toggle the MODE SET
switch until the MSPlll panel reads 201. Disengage
the idler arm on the wire drive so no wire will feed.
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F-35
F-35
TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
MACHINE LOADED TO 250 AMPS AT 26 VDC
2.0 MS/DIV
20.0 V
This is a typical DC output voltage waveform generated from a properly operating machine. Note that
each vertical division represents 20 volts and that each horizontal division represents 2.00 milliseconds in
time.
NOTE: Scope probes connected at the machine output terminals: (+) probe to electrode, (-) probe to work.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-36
F-36
TROUBLESHOOTING & REPAIR
MOTOR & GEAR BOX ASSEMBLY REMOVAL AND
REPLACEMENT
WARNING
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 precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will aid the technician in the removal and replacement of the Motor and Gear box
assembly.
MATERIALS NEEDED
3/8” Nut driver
5/16 in. Nut driver
9/16” Wrench
7/16” Wrench
Small slot head screwdriver
Large Phillips head screwdriver
Pliers
Wiring Diagram
POWER MIG 300
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F-37
F-37
TROUBLESHOOTING & REPAIR
MOTOR & GEAR BOX ASSEMBLY
REMOVAL AND REPLACEMENT (continued)
REMOVAL PROCEDURE
11. Using a Phillips head screwdriver, remove the 3
pan head screws and lock washers securing the
motor/gearbox assembly to the wire drive assem-
bly.
WARNING
ELECTRIC SHOCK can kill.
12. Grasp the motor/gearbox assembly and wiggle it
gently back and forth until it separates from the
wire drive assembly.
High voltage is present when input power is applied to
the machine.
13. Using a 5/16 in. nutdriver, remove the 3 screws
holding the wire drive compartment (with wire drive
assembly still attached) to the divider panel welded
assembly. Pull the compartment away. The motor
and gearbox can now be removed.
1. Disconnect main input power to the machine.
2. Remove the wire gun and wire.
3. Lift the tool tray door to allow access to the tool tray.
14. Using a 7/16 in. nutdriver, remove the 3 hex head
cap screws, lock washers, and flat washers secur-
ing the wire drive assembly to the wire drive com-
partment.
4. Using the 5/16 in. nutdriver, remove the tool tray (3
screws) to gain access to the motor/gearbox
assembly.
5. Disconnect motor leads 831 and 832 and tach leads
841, 844 and 847at their in-line connectors. See
the Wiring Diagram.
15. Remove the wire drive assembly from the wire
drive compartment.
For Codes 10958 & Above. See Figure F.12.
6. Using a 9/16 in. wrench, remove the bolt, lock
washer, flat washer and positive lead from the wire
drive assembly. Using pliers, remove the hose
clamp and flex hose from the wire drive assembly.
(Depends on the type of gun being used).
10. Using a 9/16 in. wrench to remove nut that holds
molded drive roll shaft assembly to the wire drive
assembly. Remove the molded drive roll shaft
assembly form the wire drive assembly.
7. Rotate the adjustment arm assembly counterclock-
wise to release the tension on the idle arm.
11. Using a 7/16 in. wrench remove panel covering the
gear.
8. Swing the idle arm up and away from the wire drive
assembly.
12. Using a Phillips head screwdriver remove gear.
13. Using a Phillips head screwdriver, remove the 3
pan head screws and lock washers securing the
motor/gearbox assembly to the wire drive assem-
bly.
9. Remove the outer guide assembly from the wire
drive assembly by loosening the thumb screws
until the outer guide can be removed. Rotate the
molded keeper until the ears line up with the slots
on the drive roll, then pull the drive roll off the shaft
assembly. Now slide off the inner guide.
14. Grasp the motor/gearbox assembly and wiggle it
gently back and forth until it separates from the
wire drive assembly.
For Codes 10952 & Below, See Figure F.11.
15. Using a 3/8 nut driver remove 6 nuts that hold
cover. Remove panel to expose drive motor.
10. Using a slotted screwdriver, remove the round
head screw, lock washer, and flat washer securing
the lower molded drive roll shaft assembly to the
wire drive assembly. Remove the molded drive roll
shaft assembly from the wire drive assembly. It
may be necessary to GENTLY pry behind the gear
to get it started off the shaft.
POWER MIG 300
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F-38
F-38
TROUBLESHOOTING & REPAIR
MOTOR & GEAR BOX ASSEMBLY
REMOVAL AND REPLACEMENT (continued)
REPLACEMENT PROCEDURE
5. Attach the flex hose and clamp.
6. Attach the tool tray.
1. Bolt the wire drive assembly to the wire drive
compartment.
2. Secure the wire drive compartment to the
divider panel welded assembly.
7. Attach the wire gun and wire.
3. Mount the motor/gearbox assembly to the wire
drive assembly and attach with screws.
4. Assemble the drive roll components to the wire
drive assembly.
FIGURE F.11
FOR CODES BELOW 10952
4
14
15
8
9
13
12
5
7
10
6
11
POWER MIG 300
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F-39
F-39
TROUBLESHOOTING & REPAIR
MOTOR & GEAR BOX ASSEMBLY
REMOVAL AND REPLACEMENT (continued)
FIGURE F.12
FOR CODES ABOVE 10958
8
10
12
11
13
15
9
14
5
6
POWER MIG 300
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F-40
F-40
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER
REMOVAL AND REPLACEMENT
WARNING
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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The procedure will aid the technician in the removal and replacement of the output rectifier
assembly.
MATERIALS NEEDED
1/2 in. Open end wrench
1/2 in. Socket wrench and extension
3/8 in. Nutdriver
3/8 in. Open end wrench
Slot head screwdriver
Diagonal cutters
Dow Corning #340 compound
POWER MIG 300
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F-41
F-41
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER
REMOVAL AND REPLACEMENT (continued)
FIGURE F.13
8
7
5
11
4
6
9
er terminal marked positive (+) . For reassembly,
note placement of the fasteners: bolt, flat washer,
heavy lead, small lead, terminal, flat washer, lock
washer, nut.
WARNING
ELECTRIC SHOCK can kill.
6. Using a slot head screwdriver and a 3/8 in. wrench,
remove Resistor R1 from the machine base. This
will provide additional clearance for accessing fas-
teners and removing the rectifier. For reassembly,
note order of the components for the resistor:
screw, star washer, plastic insulator, resistor, plastic
insulator. This assembly rests on top of the
machine base. From beneath the base a flat wash-
er, lock washer, and nut attach to the screw. It is a
good practice to loosely assemble the parts and set
the resistor aside until ready to be reassembled.
High voltage is present when input power is applied to
the machine.
NOTE: Cut cable ties as needed to improve access.
See Figure F.13 for the following procedure.
1. Disconnect main input power from the machine.
2. Perform the Chopper Board Capacitor Discharge
7. Using a 1/2 in. wrench and a 1/2 in. socket wrench
with extension, remove heavy lead X2 from the ter-
minal at the top of the rectifier, near side. For
reassembly, note placement of the fasteners: bolt,
flat washer, heavy lead, terminal, lock washer, nut.
Procedure.
3. Remove the right side panel using a 3/8 in. nutdriv-
er. (as viewed from the front of machine).
4. Using the 1/2 in. wrenches, remove heavy lead B1
and small resistor lead 2530 from the output rectifi-
er lower terminal, marked negative (-) . For
reassembly, note placement of the fasteners: bolt,
flat washer, heavy lead, small lead, terminal, flat
washer, lock washer, nut.
8. Using a 1/2 in. wrench and a 1/2 in. socket wrench
with extension, remove heavy lead X1 (from the
output choke) from the other terminal at the top of
the rectifier, nearer to the chopper board assembly.
For reassembly, note placement of the fasteners:
bolt, flat washer, heavy lead, terminal, lock washer,
nut.
5. Using the 1/2 in. wrenches, remove heavy lead B5
and small resistor lead 2520 from the output rectifi-
POWER MIG 300
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F-42
F-42
TROUBLESHOOTING & REPAIR
OUTPUT RECTIFIER
REMOVAL AND REPLACEMENT (continued)
9. Using a 3/8 in. wrench, remove the 4 nuts and lock
washers holding the rectifier bracket to the machine
base.
10. Clear the leads and carefully remove the output
rectifier assembly.
11. With a 1/2 in. wrench, loosen the3 nuts holding the
rectifier to its bracket.
REPLACEMENT PROCEDURE
NOTE: When installing the output rectifier assembly,
apply a thin coating of Dow Corning #340 com-
pound to the electrical connections.
1. Fit the new output rectifier into its bracket.
2. Install the output rectifier. Fasten it to the machine
base with 4 lock washers and nuts.
3. Install heavy leads X1 and X2 to the terminals at the
top of the output rectifier. X1 mounts to the termi-
nal nearer to the chopper board assembly. Note
placement of fasteners as described above.
4. Install resistor R1.
5. Install heavy lead B5 and resistor lead 2520 to the
lower terminal, marked (+).
6. Install heavy lead B1 and resistor lead 2530 to the
upper terminal, marked (-).
7. Replace any cable ties removed for disassembly.
8. Install the case side panels.
POWER MIG 300
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F-43
F-43
TROUBLESHOOTING & REPAIR
CHOPPER BOARD ASSEMBLY REMOVAL
AND REPLACEMENT
WARNING
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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in the removal and replacement of the Chopper
Board assembly. The assembly is replaced as a unit; there are no serviceable parts.
MATERIALS NEEDED
5/16 in. Nutdriver
3/8 in. Nutdriver or wrench
7/16 in. Open end wrench
1/2 in. Open end wrench
1/2 in. Socket wrench, universal tool, and extension
3/8 in. Nutdriver
3/8 in. Open end wrench
Diagonal cutters
Wiring Diagram
POWER MIG 300
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F-44
F-44
TROUBLESHOOTING & REPAIR
CHOPPER BOARD ASSEMBLY REMOVAL
AND REPLACEMENT (continued)
FIGURE F.14 – CHOPPER BOARD ASSEMBLY DETAILS
9
12
8
23D
10
7
12
4
6
Leads B8 & B7
(other side of chopper board)
6. Disconnect lead 607 from terminal B8 and lead 613
from terminal B7 at their in-line connectors.
REMOVAL PROCEDURE
WARNING
7. Using a 7/16 in. wrench, remove heavy lead B8 (to
negative output terminal) and B2 (to choke) from
the chopper board.
ELECTRIC SHOCK can kill.
High voltage is present when input power is applied to
the machine.
8. Using a 7/16 in. wrench, remove heavy leads B1
and B5 (to output rectifier) from the chopper board.
9. Using the 5/16 in. nutdriver, remove the 4 screws
holding the fan baffle to the machine base. This
will allow you to move the baffle back out of the
way to access the right rear nut on the chopper
assembly bracket.
NOTE: Cut cable ties as needed to improve access.
See Figure F.14 for the following procedure.
1. Disconnect main input power from the machine.
10. Using the 3/8 in. wrench or nutdriver, remove the 4
nuts holding the chopper assembly brackets to the
machine base.
2. Perform the Chopper Board Capacitor Discharge
Procedure.
3. Remove the case side panels using a 3/8 in. nut-
driver.
11. Carefully remove the chopper assembly from the
machine.
4. Label and disconnect thermostat leads 503 and
503A.
12. Using a 7/16 in. wrench, remove the 2 support
brackets from the chopper board assembly.
5. Unplug J99 from the chopper board.
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F-45
F-45
TROUBLESHOOTING & REPAIR
CHOPPER BOARD ASSEMBLY REMOVAL
AND REPLACEMENT (continued)
REPLACEMENT PROCEDURE
1. Attach the chopper assembly brackets to the new
chopper assembly.
2. Install the chopper board assembly. Fasten it to the
machine base with 4 lock washers and nuts.
3. Install heavy leads B1 and B5.
4. Install heavy leads B6 and B2.
5. Connect lead 607 (B8) and lead 613 (B7) at their in-
line connectors.
6. Connect plug J99.
7. Connect thermostat leads 503 and 503A.
8. Install the case side panels.
POWER MIG 300
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F-46
F-46
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND
REPLACEMENT
WARNING
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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The procedure will aid the technician in the removal and replacement of the main trans-
former and choke assembly.
MATERIALS NEEDED
5/16 in. Nutdriver
3/8 in. Nutdriver or open end wrench
1/2 in. Open end wrench
1/2 in. Socket wrench and extension
9/16 in. Open end wrench
Diagonal cutters
Phillips head screwdriver
POWER MIG 300
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F-47
F-47
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND
REPLACEMENT (continued)
REMOVAL PROCEDURE
5. Remove gun.
WARNING
6. Remove work lead from output stud.
CASE FRONT ASSEMBLY REMOVAL
7. Remove the case front assembly as follows:
ELECTRIC SHOCK can kill.
High voltage is present when input power is applied to
the machine.
a. Using a phillips head screwdriver, remove the 2
screws holding the line switch to the case front.
b. Using a 5/16 in. nutdriver, remove 10 screws hold-
ing the case front to the to the machine base and
center assembly.
NOTE: Cut cable ties as needed to improve access.
PREPARATION
c. Lift the case front upward and forward slightly, then
disconnect plug J34 from the MSP3 mode select
panel. The case front assembly can now be
removed. See Figure F.13.
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. Remove the case top using a 3/8 in. nutdriver.
POWER MIG 300
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F-48
F-48
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND
REPLACEMENT (continued)
assembly can now be lifted enough to allow the
main transformer and choke assembly to be
removed.
LEAD DISCONNECTION
8. Using a phillips head screwdriver, remove fan lead
X4 from fan relay terminal #1 and disconnect fan
lead X3 from its in-line connector at the fan motor.
Cut cable ties as needed pull the leads through the
baffles to clear them.
18. With the help of an assistant, lift the front of the
center assembly and slide the main transformer
and choke assembly out through the front of the
machine. Use care -- the assembly is very heavy.
9. Using a 1/2 in. wrench, disconnect leads X1 and X2
from the output rectifier. Note the order of the fas-
teners for reassembly: bolt, flat washer, heavy
lead, terminal, lock washer, nut.
REPLACEMENT PROCEDURE
For lead reassembly steps, also see the Wiring
Diagram.
10. Disconnect leads X5 and X6 from the control recti-
fier (spade connectors).
1. With the help of an assistant, carefully slide the new
transformer/choke assembly into place. Attach it to
the machine base with 4 bolts, lock washers, and
nuts.
11. Disconnect thermostat leads 502 and 503A from
their in-line connectors (right side of the machine).
12. Using a 3/8 in. nutdriver, disconnect leads H2, H3,
and H5 from the reconnect panel terminals 2, 3,
and 5.
2. Attach the right and left transformer baffles to the
machine base (1 screw each side).
3. Connect the heavy lead from the top of the choke to
the positive output terminal.
13. Using a 3/8 in. driver, disconnect leads H1 and H4
from the back of the line switch. Looking at the
back of the switch, H1 is at the bottom right and H4
is at the bottom left. Note that leads H1 and H4,
which go to the reconnect panel, attach at these
same terminals.
4. Connect heavy lead B2 to the choke.
5. Connect leads H1 and H4 to the back of the line
switch. See disassembly step for details.
14. Using a 1/2 in. wrench and socket wrench, discon-
nect heavy lead B2 from the choke.
6. Connect leads H2, H3, and H5 to the reconnect
panel.
15. Using a 9/16 in. wrench and socket wrench, dis-
connect the heavy lead from the choke to the pos-
itive output terminal. It is not necessary to remove
any other leads; screw the bolt with leads still
attached back into the positive output terminal until
reassembly.
7. Connect thermostat leads 502 and 503A at their in-
line connectors (right side of the machine).
8. Connect leads X5 and X6 to the control rectifier
(spade connectors).
9. Connect leads X1 and X2 to the output rectifier.
Note the order of the fasteners: bolt, flat washer,
heavy lead, terminal, lock washer, nut.
MAIN TRANSFORMER AND CHOKE
ASSEMBLY REMOVAL
10. Connect fan lead X4 to fan relay terminal 1 and fan
lead X3 at its in line connector at the fan motor.
16. Using a 1/2 in. socket wrench, remove 4 nuts and
lock washers that hold the main transformer to the
machine base. Also remove the 4 in. bolts from
underneath.
11. Install the case front assembly. Connect plug J34
and mount the line switch.
12. Install new cable ties as needed.
13. Install the case sides and top.
17. Using a 5/16 in. nutdriver, remove the 2 screws that
hold the right and left transformer baffle in place (1
screw each). The center assembly and rear
POWER MIG 300
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F-49
F-49
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND
REPLACEMENT (continued)
FIGURE F.15
12
8
7C
15
9
BACK
SIDE
5
10
UNDER
PANEL
11
6
14
7B
16
TEN
(10)
17
13
7A
BACK
SIDE
POWER MIG 300
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F-50
F-50
TROUBLESHOOTING & REPAIR
FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT
WARNING
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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The procedure will aid the technician in the removal and replacement of the fan motor
assembly.
MATERIALS NEEDED
3/8 in. Nutdriver
11/32 in. Open end wrench
Diagonal cutters
Slot or phillips head screwdriver
POWER MIG 300
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F-51
F-51
TROUBLESHOOTING & REPAIR
FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT
(continued)
FIGURE F.16 – FAN MOTOR ASSEMBLY REMOVAL
4A
4B
6
6
5
6. Remove the fan motor.
REMOVAL PROCEDURE
a. Loosen and remove the two nuts and lock wash-
ers from the motor mounting bracket using a
11/32 in. open end wrench.
1. Disconnect main input power to the machine.
2. Remove the case side panels using a 3/8 in. nut-
driver.
b. When the motor is free from the mounting brack-
et, slide the motor from the POWER MIG unit.
3. Cut the wire tie from around the fan motor leads.
4. Disconnect fan motor leads:
REPLACEMENT PROCEDURE
a. Unplug the black lead from its in-line connector.
1. Attach the fan motor to the mounting bracket.
b. Using a slot or phillips head screw driver, dis-
connect the white lead at the fan relay. See
Figure F.16.
2. Install the fan blade and tighten the fan blade
clamp. Ensure the fan is in the same position on
the shaft as it was prior to removal. Spin the fan to
be sure it is free to rotate.
5. Remove the fan blade. Note the position of the fan
on the shaft for reassembly.
3. Connect the fan motor leads: black at its in-line con-
nector and white at fan relay terminal 1.
a. Using a slot head screwdriver, loosen the fan
blade clamp.
4. Install the case sides.
b. Slide the fan blade off the motor shaft.
POWER MIG 300
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F-52
F-52
TROUBLESHOOTING & REPAIR
VOLTAGE & CURRENT CALIBRATION PROCEDURE
WARNING
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 precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will determine if the machine is capable of producing welding output as well as check
and adjust, if necessary, the voltage and or current calibration.
MATERIALS NEEDED
Resistive Load Bank
Calibrated Test Voltmeter
Calibrated Test Ammeter
POWER MIG 300
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F-53
F-53
TROUBLESHOOTING & REPAIR
VOLTAGE & CURRENT CALIBRATION PROCEDURE (continued)
NOTE: Before attempting to calibrate the voltage
CALIBRATION CHECK (CODE 10562)
or current setting of the Power Mig, be
The calibration of the Power Mig 300 can be
sure to read the entire voltage or current
checked using a resistive load bank with the
calibration procedure. If the steps are not
Power Mig 300 in mode 200. Mode 200 is a con-
completed quickly, the machine will auto-
stant current test mode.
matically leave the calibration mode with-
out changing the calibration settings. The
voltage and current calibration settings of
the Power Mig are completely indepen-
dent of each other. Adjusting one will not
affect the other.
1. Toggle and hold the mode select switch in the
up position.
2. Turn on the Power Mig 300.
3. Rotate the output knob, while still holding the
mode select switch up, until the display reads
“ALL nodE”.
VOLTAGE CALIBRATION
1. Connect the resistive load bank (approximate-
ly .106 ohms or 250 amps) and test voltmeter
to the welding output terminals.
4. Release the mode select switch, toggle the
mode switch one more time, then toggle the
MODE SET switch until the MSPlll panel
reads 200. Disengage the idler arm on the
wire drive so no wire will feed.
2. Toggle and hold in the mode select switch in
the up position.
3. Turn on the Power Mig 300.
5. With the machine in mode 200 apply a resis-
tive to the welding output terminals (approx.
.106 ohms) set the machine output to 250
amps and enable the weld terminals by
pressing the trigger switch.
4. Rotate the right hand output control knob until
the display reads “vol cAL”.
5. Release the mode select switch.
6. Using the test meters note the output voltage
and current.
6. The left display will change to “VcAL” to indi-
cate that voltage calibration is in progress.
7. The Power Mig 300 voltmeter must match the
test meter reading to within +/- 1 volt.
7. The right hand display will scroll the following
message: Adj rEnc SorEAL vol = 20V.
8. The Power Mig 300 ammeter must match the
test meter within +/- 5 amps.
8. Adjust output control knob until the actual out-
put voltage reading on the test volt meter is 20
volts +/- .5 volts.
9. If the volt meter does not meet the specifica-
tion then proceed to the Voltage Calibration
Procedure.
10. If the ammeter does not meet the specifica-
tion then proceed to the Current Calibration
Procedure.
POWER MIG 300
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F-54
F-54
TROUBLESHOOTING & REPAIR
VOLTAGE & CURRENT CALIBRATION PROCEDURE (continued)
9. Wait for the machine’s output to be automati-
cally turned off and then back on.
5. Release the mode select switch.
6. The left display will change to “lcAL” to indi-
cate that current calibration is in progress.
10. Adjust the output control knob again if neces-
sary to make the actual voltage output 20
volts +/- .5 volts.
7. The right hand display will scroll the following
message: Adj rEnc SorEAL cur = 250A.
11. Wait for the machine’s output to be automati-
cally turned off and then back on.
8. Adjust the right hand output control knob until
the actual output current reading on the test
ammeter is 250 amps +/- 2A.
12. Repeat the above two steps if necessary.
13. Toggle the mode select switch up and release
the switch to save the calibration setting.
9. Wait for the machine’s output to be automati-
cally turned off and then back on.
14. The right display will display the message
“VcAL SAVEd”. Within 5 seconds, hold the
mode set switch in the up position until the
right display stops blinking.
10. Adjust the output control knob again if neces-
sary to make the actual output current read-
ing on the test ammeter 250 amps +/- 2A.
11. Wait for the machine’s output to be automati-
cally turned off and then back on.
15. The machine will reset to normal operation
after a few seconds.
12. Repeat the above two steps if necessary.
NOTE: If the mode select switch is not toggled
within 30 seconds after adjusting the out-
put control knob, the machine will leave
the calibration mode and use the previ-
ous calibration settings.
13. Toggle the mode select switch up and release
the switch to save the calibration setting.
14. The right display will display the message
“lcAL SAVEd”. Within 5 seconds, hold the
mode set switch in the up position until the
right display stops blinking.
CURRENT CALIBRATION
PROCEDURE
1. Connect the resistive load bank of approx.
.106 ohms and test ammeter to the welding
output terminals.
15. The machine will reset to normal operation
after a few seconds.
2. Toggle and hold the mode select button in the
up position.
NOTE: If the mode select switch is not toggled
within 30 seconds after adjusting the out-
put control knob, the machine will leave
the calibration mode and use the previ-
ous calibration settings.
3. Turn on the Power Mig 300.
4. Rotate the output control knob until the dis-
play reads “cur cAL”.
POWER MIG 300
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F-55
F-55
TROUBLESHOOTING & REPAIR
VOLTAGE & CURRENT CALIBRATION PROCEDURE (continued)
NOTE: Before attempting to calibrate the voltage
CALIBRATION CHECK
(CODES 10952 AND UP)
or current setting of the Power Mig, be
sure to read the entire voltage or current
The calibration of the Power Mig 300 can be
checked using a resistive load bank with the
Power Mig 300 in mode 200. Mode 200 is a con-
stant current test mode.
calibration procedure. If the steps are not
completed quickly, the machine will auto-
matically leave the calibration mode with-
out changing the calibration settings. The
voltage and current calibration settings of
the Power Mig are completely indepen-
dent of each other. Adjusting one will not
affect the other.
1. Toggle and hold the mode select switch in the
up position.
2. Turn on the Power Mig 300.
VOLTAGE CALIBRATION
1. Connect the resistive load bank (approximate-
ly .106 ohms) and test voltmeter to the weld-
ing output terminals.
3. Once the display reads “Pres Spin” release
the mode select switch. Rotate the output
knob until the display reads “ALL nodE”.
2. Toggle and hold in the mode select switch in
the up position.
4. Toggle the Mode Select switch once and wait
for the machine to reset, then toggle the
MODE SET switch until the MSPlll panel
reads 200. Disengage the idler arm on the
wire drive so no wire will feed.
3. Turn on the Power Mig 300.
4. Once the display reads “Pres Spin” release
the mode select switch. Rotate the output
knob until the display reads “vol cAL”.
5. With the machine in mode 200 apply a resis-
tive to the welding output terminals (approx.
.106 ohms) set the machine output to 250
amps and enable the weld terminals by
pressing the trigger switch.
5. Release the mode select switch once.
6. Using the test meters note the output voltage
and current.
6. The left display will change to “VcAL” to indi-
cate that voltage calibration is in progress.
7. The Power Mig 300 voltmeter must match the
test meter reading to within +/- 1 volt.
7. The right hand display will scroll the following
message: Adj rEnc SorEAL vol = 20V.
8. The Power Mig 300 ammeter must match the
test meter within +/- 5 amps.
8. Adjust output control knob until the actual out-
put voltage reading on the test volt meter is 20
volts +/- .5 volts.
9. If the volt meter does not meet the specifica-
tion then proceed to the Voltage Calibration
Procedure.
10. If the ammeter does not meet the specifica-
tion then proceed to the Current Calibration
Procedure.
POWER MIG 300
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F-56
F-56
TROUBLESHOOTING & REPAIR
VOLTAGE & CURRENT CALIBRATION PROCEDURE (continued)
9. Wait for the machine’s output to be automati-
cally turned off and then back on.
5. Toggle the Mode Select switch once.
6. The left display will change to “lcAL” to indi-
cate that current calibration is in progress.
10. Adjust the output control knob again if neces-
sary to make the actual voltage output 20
volts +/- .5 volts.
7. The right hand display will scroll the following
message: Adj rEnc SorEAL cur = 250A.
11. Wait for the machine’s output to be automati-
cally turned off and then back on.
8. Adjust the right hand output control knob until
the actual output current reading on the test
ammeter is 250 amps +/- 2A.
12. Repeat the above two steps if necessary.
13. Toggle the mode select switch up and release
the switch to save the calibration setting.
9. Wait for the machine’s output to be automati-
cally turned off and then back on.
14. The right display will display the message
“VcAL SAVEd”. Within 5 seconds, hold the
mode set switch in the up position until the
right display stops blinking.
10. Adjust the output control knob again if neces-
sary to make the actual output current read-
ing on the test ammeter 250 amps +/- 2A.
11. Wait for the machine’s output to be automati-
cally turned off and then back on.
15. The machine will reset to normal operation
after a few seconds.
12. Repeat the above two steps if necessary.
NOTE: If the mode select switch is not toggled
within 30 seconds after adjusting the out-
put control knob, the machine will leave
the calibration mode and use the previ-
ous calibration settings.
13. Toggle the mode select switch up and release
the switch to save the calibration setting.
14. The right display will display the message
“lcAL SAVEd”. Within 5 seconds, hold the
mode set switch in the up position until the
right display stops blinking.
CURRENT CALIBRATION
PROCEDURE
1. Connect the resistive load bank of approx.
.106 ohms and test ammeter to the welding
output terminals.
15. The machine will reset to normal operation
after a few seconds.
2. Toggle and hold the mode select button in the
up position.
NOTE: If the mode select switch is not toggled
within 30 seconds after adjusting the out-
put control knob, the machine will leave
the calibration mode and use the previ-
ous calibration settings.
3. Turn on the Power Mig 300.
4. Once the display reads “Pres Spin” release
the mode select switch. Rotate the output
knob until the display reads “cur cAL”.
POWER MIG 300
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F-57
F-57
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
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 WATTS AND AMPS
Input Volts/Hertz
Maximum Idle Watts
Maximum Idle Amps
230/60
400
4.25
OPEN CIRCUIT VOLTAGE
45-49 VDC
WIRE SPEED RANGE
50 - 700 IPM (1.27 - 17.8 m/minute)
OUTPUT
AMPS
VOLTS
200A
27-30
POWER MIG 300
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G
WIRING DIAGRAM (CODE 10562 ONLY-G3852). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
WIRING DIAGRAM (CODE 10952 ONLY-G4068). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3
WIRING DIAGRAM (CODE 10958 AND 11000 ONLY-G4305) . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
WIRING DIAGRAM (CODE 11097 AND 11098 ONLY-G4511) . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
ENTIRE MACHINE SCHEMATIC (CODE 10958 and 11000 ONLY-G4315). . . . . . . . . . . . . . . . . G-6
ENTIRE MACHINE SCHEMATIC (CODE 11097 and 11098 ONLY-G4512) . . . . . . . . . . . . . . . . . G-7
CONTROL PC BOARD SCHEMATIC #1 (CODE 10562 - 11098 - G3789-1D0/1) . . . . . . . . . . . . G-8
CONTROL PC BOARD SCHEMATIC #2 (CODE 10562 - 11098 - G3789-1D0/2) . . . . . . . . . . . . G-9
CONTROL PC BOARD SCHEMATIC #3 (CODE 10562 - 11098 - G3789-1D0/3) . . . . . . . . . . . . G-10
CONTROL PC BOARD SCHEMATIC #4 (CODE 10562 - 11098 - G3789-1D0/4) . . . . . . . . . . . . G-11
CONTROL PC BOARD ASSEMBLY (CODE 10562 - 11098 - L11088-1) . . . . . . . . . . . . . . . . . . . *
POWER SUPPLY PC BOARD SCHEMATIC (CODE 10562 - 11098 - G3631) . . . . . . . . . . . . . . G-12
POWER SUPPLY PC BOARD ASSEMBLY (CODE 10562 - 11098 - G3632-2). . . . . . . . . . . . . . *
CHOPPER PC BOARD SCHEMATIC (CODE 10562 - 11098 - M20046-1L2) . . . . . . . . . . . . . . . G-13
CHOPPER PC BOARD ASSEMBLY (CODE 10562 - 11098 - L11497-1). . . . . . . . . . . . . . . . . . . *
MSP3 PC BOARD SCHEMATIC (CODE 10562 - 11098 - L11612) . . . . . . . . . . . . . . . . . . . . . . . G-14
MSP3 PC BOARD ASSEMBLY(CODE 10562 - 11098 - M19790-1). . . . . . . . . . . . . . . . . . . . . . . G-15
FEEDER PC BOARD SCHEMATIC (CODE 10562 - 11098 - G3883 - SHEET 1) . . . . . . . . . . . . G-16
FEEDER PC BOARD SCHEMATIC (CODE 10562 - 11098 - G3883 - SHEET 2) . . . . . . . . . . . . G-17
FEEDER PC BOARD ASSEMBLY (CODE 10562 - 11098 - G3884) . . . . . . . . . . . . . . . . . . . . . . *
SPOOL GUN PC BOARD SCHEMATIC (CODE 10562 - 11098 - G3997 - SHEET 1). . . . . . . . . G-18
SPOOL GUN PC BOARD SCHEMATIC (CODE 10562 - 11098 - G3997 - SHEET 2). . . . . . . . . G-19
SPOOL GUN PC BOARD ASSEMBLY (CODE 10562 - 11098 - M20159-1) . . . . . . . . . . . . . . . . *
ENCODER PC BOARD SCHEMATIC (CODE 10562 ONLY - L11558) . . . . . . . . . . . . . . . . . . . . G-20
ENCODER PC BOARD ASSEMBLY (CODE 10562 ONLY - L11559-2) . . . . . . . . . . . . . . . . . . . . G-21
DISPLAY PC BOARD SCHEMATIC (CODE 10562 - 11098 - L11108) . . . . . . . . . . . . . . . . . . . . . G-22
DISPLAY PC BOARD ASSEMBLY (CODE 10562 - 11098 - L11757-1) . . . . . . . . . . . . . . . . . . . . G-23
* NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unservice-
able. The Assembly numbers are provided on this page but the actual drawings are no longer included.
POWER MIG 300
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - POWER MIG 300 CODE 10562 ONLY
S3RS232
CONNECTOR
1
DIGITAL POWE R SUPPLY BOARD
DISPLAY
BOARD
ENCODER
BOARD
MS P III
BOARD
CONTROL
BOARD
3233 471
253
254
2
3
+
472
C6
6800/75
3234
253
251
4
254
5
472B
L2
L9
471B
6
FLEX CIRCUIT
1
2
X5
X6
SHIELDED
CABLE
251
7
CONTROL
RECTIFIER
-
20
+
3
SPOOL GUN
BOARD
FEEDER
BOARD
431
1104
406 402
471
472
412 408 410
411 407
403
437 405
401
4
1103
5
L6
L7
SHIELDED
CABLE
J3
6
FAN
MOTOR
7
SHIELDED
CABLE
8
9
FAN
RELAY
+
-
FAN
715
716
10
~
P.C. BOARD CONNECTION DETAIL
X5
X6
401
402
403
1
2
437
431
3
4
405
406
407
408
5
H1
J99
B1
B2
503
503A
B2
6
X3
J4
C1
C2
C3
B4
7
H5 H2 H3 H4
H1
8
L1
CHOKE
B1
B5
115V
B5
9
(SHOWN
CONNECTED
FOR 230V)
+S TUD
901B
L1
L2
410
411
412
10
11
12
901
X4
X1
H2
C4
B6
B3
TP4
L1
L2
LINE
SWITCH
2520
2530
H5
H3
RECONNECT PANEL
H4
H1
R2
903B
1
2
3
4
R1
C5
2400/100
502
503
TP6
W
B
H1
H1
C
O
N
T
J5
LEM
H4
-STUD
G
H4
X2
B6
MS P III BOAR D
TP5
502
503A
1
2
SET
SELECT
SWITCH
3417
1
2
3
4
3411
1
2
3
4
5
6
7
8
3
SWITCH
3415
604
607
903
4
802 801
804 806
R
O
L
TO +
STUD
5
3411A
3411
3411A
3416
3414
3415
3416
3417
6
J341
GND
4A
4
7
3414
300A CHOPPER BOARD
GEARBOX
2
8
E
D
2A
75
75A
76
FOOT
AMPTROL
J6
WIRE
DR IVE
MOTOR
9
F
C
DISPLAY
SHIELDED
CABLE
J37
J36
FLEX
604
611
10
11
12
13
14
15
16
A
B
AMPHENOL
P.C. BOARD
76A
B
77
1
2
77A
(VIEWED
FROM
831:B 832:W
O
A
R
L3
DIODE
BRIDGE
ENCODER
FLEX
REAR)
76A
3
P.C. BOARD
4A
E
G
B
4
SPOOL GUN/
PUSH-PULL
AMPHENOL
F
2A
D
J361
615
75A
3218
3214
5
C
A
833
SHIELDEDCABLE
J34
GUN TRIGGER
6
TACH
D
77A
7
1
2
3
4
L4
L5
1
2
GAS
SOLENOID
8
LOCATED ON
CASE FRONT
9
3
L8
SPOOL GUN/
PUSH-PULL
SWITCH
10
4
834
5
6
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
7
FLEX
75
3214
2
3218
3234
3233
3244
3243
832:W 834 836
831:B 833 835
852
8
841:R
76
4
77
844:B
855
8512
847:U
851
J7
9
G=GREEN (W/YELLOW STRIPE)
10
11
12
13
14
15
16
1
6
4
1
5
1
3
1
2
4
1
5
8
4
6
3
10
2
1
8
1
6
7
1
715
716
7
12
9
16
6
14
CONNECTOR CAVITY NUMBER ING SEQUENCE
(VIEWED FROMCOMPONENT SIDE OF BOARD)
801
802
1
2
3
4
5
6
7
8
FEEDER BOARD
SPI SPOOL GUN BOARD
L2 THRU L9ARE RF CHOKES
804
806
J8
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE
(VIEWED FROM LEAD SIDE OF RECEPTACLE)
3244
1101
1102 3243
1102 1104
1101 1103
901 903
3
6
9
2
5
8
1
4
7
1 2 3
4 5 6
7 8 9
SHIELDEDCABLE
9 PIN
J50
9 PIN
P50
12 -21- 2001A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER MIG 300
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G-3
G-3
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - POWER MIG 300 CODE 10952 ONLY
S3RS232
CONNECTOR
1
DIGITAL POWE R SUPPLY BOARD
DISPLAY
BOARD
MS P III
BOARD
CONTROL
BOARD
3233 471
253
254
2
3
+
472
C6
6800/75
3234
253
251
4
254
5
472B
L2
L9
471B
6
FLEX CIRCUIT
1
2
X5
X6
SHIELDED
CABLE
251
7
CONTROL
RECTIFIER
-
20
+
3
SPOOL GUN
BOARD
FEEDER
BOARD
431
1104
406 402
471
472
412 408 410
411 407
403
437 405
1103
401
4
5
L6
L7
SHIELDED
CABLE
J3
6
FAN
MOTOR
7
SHIELDED
CABLE
8
9
FAN
RELAY
+
-
FAN
715
716
10
~
P.C. BOARD CONNECTION DETAIL
X5
X6
401
402
403
1
2
437
431
3
4
405
406
407
408
5
H1
J99
B1
503
503A
B2
6
X3
J4
C1
C2
C3
B4
300A CHOPPER BOARD
7
H5 H2 H3 H4
H1
8
L1
CHOKE
B1
115V
B5
B2
9
(SHOWN
CONNECTED
FOR 230V)
+S TUD
901B
L1
L2
410
411
412
B5
901
10
11
12
X4
X1
H2
C4
B6
B3
TP4
L1
L2
LINE
SWITCH
2520
H5
H3
RECONNECT PANEL
H4
H1
R2
903B
1
2
3
4
R1
C5
2400/100
502
503
TP6
W
B
H1
H1
C
O
N
T
R
O
L
J5
LEM
2530
H4
-STUD
G
H4
X2
B6
MS P III BOAR D
TP5
502
503A
1
2
SET
SELECT
SWITCH
3417
1
2
3
4
3411
1
2
3
4
5
6
7
8
3
SWITCH
3415
604
607
903
4
802 801
804 806
TO +
STUD
5
3411A
3411
3411A
3416
3414
3415
3416
3417
6
J341
GND
4A
4
7
3414
GEARBOX
2
8
E
D
2A
75
75A
76
DISPLAY
P.C. BOARD
FOOT
AMPTROL
AMPHENOL
J6
WIRE
DR IVE
MOTOR
J37
FLEX
9
F
C
604
611
10
11
12
13
14
15
16
A
B
76A
B
GUN
TRIGGER
77
77A
(VIEWED
FROM
REAR)
PANEL ENCODERS
VOLTS/TRIM WFS/AMPS
831:B 832:W
O
A
R
2
3
L3
DIODE
BRIDGE
1
2
3
4
76A
3
2
1
3
2
1
4A
E
G
B
4
SPOOL GUN/
PUSH-PULL
AMPHENOL
D
F
2A
615
SPOOL GUN/
PUSH-PULL
SWITCH
75A
3218
3214
5
C
A
833
SHIELDEDCABLE
J34
6
TACH
D
77A
7
L4
L5
1
2
GAS
SOLENOID
8
852
855A
9
3
8511 858
857 8510
859
855
8512
851
L8
10
4
834
5
FLEX
6
7
75
3214
2
3218
3234
3233
3244
3243
832 834 836
8
841:R
76
4
77
831 833 835
844:B
847:U
J7
9
10
11
12
13
14
15
16
LEAD COLOR CODE:
B=BLACK OR GRAY
R=REDOR PINK
W=WHITE
4
3
1
2
4
1
1
1
5
715
716
8
1
4
6
3
2
G=GREEN (W/YELLOW STRIPE)
1
1
6
5
1
8
7
801
802
1
2
3
4
5
6
7
8
FEEDER BOARD
SPI SPOOL GUN BOARD
7
12
6
10
9
16
6
14
CONNECTOR CAVITY NUMBER ING SEQUENCE
(VIEWED FROMCOMPONENT SIDE OF BOARD)
804
806
J8
L2 THRU L9ARE RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
3244
1101
1102 3243
1102 1104
1101 1103
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE
(VIEWED FROM LEAD SIDE OF RECEPTACLE)
901 903
3
6
9
2
5
8
1
4
7
1 2 3
4 5 6
7 8 9
SHIELDEDCABLE
9 PIN
J50
9 PIN
P50
A
G4068
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER MIG 300
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G-4
G-4
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - POWER MIG 300 CODE 10958 AND 11000 ONLY
S3RS232
CONNECTOR
1
DIGITAL POWE R SUPPLY BOARD
DISPLAY
BOARD
MS P III
BOARD
CONTROL
BOARD
3233 471
253
254
2
3
+
472
C6
6800/75
3234
253
251
4
254
5
472B
L2
L9
471B
6
FLEX CIRCUIT
1
2
X5
X6
SHIELDED
CABLE
251
7
CONTROL
RECTIFIER
-
20
+
3
SPOOL GUN
BOARD
FEEDER
BOARD
431
1104
406 402
471
472
412 408 410
411 407
403
437 405
1103
401
4
5
L6
L7
SHIELDED
CABLE
J3
6
FAN
MOTOR
7
SHIELDED
CABLE
8
9
FAN
RELAY
+
-
FAN
715
716
10
~
P.C. BOARD CONNECTION DETAIL
X5
X6
401
402
403
1
2
437
431
3
4
405
406
407
408
5
H1
J99
B1
B2
503
503A
B2
6
X3
J4
C1
C2
C3
B4
300A CHOPPER BOARD
7
H5 H2 H3 H4
H1
8
L1
CHOKE
B1
115V
B5
9
(SHOWN
CONNECTED
FOR 230V)
+S TUD
901B
L1
L2
410
411
412
B5
901
10
11
12
X4
X1
H2
C4
B6
B3
TP4
L1
L2
LINE
SWITCH
2520
H5
H3
RECONNECT PANEL
H4
H1
R2
903B
1
2
3
4
R1
C5
2400/100
502
503
TP6
W
B
H1
H1
C
O
N
T
R
O
L
J5
LEM
2530
H4
-STUD
G
H4
X2
B6
MS P III BOAR D
TP5
502
1
2
SET
SELECT
SWITCH
3417
1
2
3
4
3411
1
2
3
4
5
6
7
8
503A
3
SWITCH
3415
604
607
903
4
802 801
804 806
TO +
STUD
5
3411A
3411
3411A
3416
3414
3415
3416
3417
6
J341
GND
4A
4
7
3414
DIODE
BRIDGE
2
GEARBOX
8
E
D
B
2A
75
75A
76
DISPLAY
P.C. BOARD
FOOT
AMPTROL
AMPHENOL
J6
J37
FLEX
WIRE
DR IVE
MOTOR
9
F
C
604
611
10
11
12
13
14
15
16
TACH
A
76A
B
GUN
TRIGGER
77
77A
(VIEWED
FROM
REAR)
PANEL ENCODERS
VOLTS/TRIM WFS/AMPS
W
B
O
A
R
2
3
L3
1
2
3
4
76A
L8
3
2
1
3
2
1
4A
E
G
B
4
SPOOL GUN/
PUSH-PULL
AMPHENOL
D
F
2A
615
SPOOL GUN/
PUSH-PULL
SWITCH
75A
3218
3214
5
C
A
833
SHIELDEDCABLE
J34
6
D
77A
7
L4
L5
1
2
GAS
8
SOLENOID
B
W
852
855A
9
3
8511 858
857 8510
859
855
8512
851
10
4
834
5
FLEX
6
7
75
3214
2
3218
3234
3244
3243
832 834 836
8
841:R
76
4
77
3233
831 833 835
844:B
847:U
J7
9
10
11
12
13
14
15
16
LEAD COLOR CODE:
B=BLACK OR GRAY
R=REDOR PINK
W=WHITE
4
3
1
2
4
1
1
1
5
715
716
8
1
4
6
3
2
G=GREEN (W/YELLOW STRIPE)
1
1
6
5
1
8
7
801
802
1
2
3
4
5
6
7
8
FEEDER BOARD
SPI SPOOL GUN BOARD
7
12
6
10
9
16
6
14
CONNECTOR CAVITY NUMBER ING SEQUENCE
(VIEWED FROMCOMPONENT SIDE OF BOARD)
804
806
J8
L2 THRU L9ARE RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
3244
1101
1102 3243
1102 1104
1101 1103
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE
(VIEWED FROM LEAD SIDE OF RECEPTACLE)
901 903
3
6
9
2
5
8
1
4
7
1 2 3
4 5 6
7 8 9
SHIELDEDCABLE
9 PIN
J50
9 PIN
P50
B
G4305
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER MIG 300
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - POWER MIG 300 CODE 11097 AND 11098 ONLY
S3 RS232
CONNECTOR
1
DIGITAL POWER SUPPLY BOARD
DISPLAY
BOARD
MSP III
BOARD
CONTROL
BOARD
3233 471
253
254
2
3
+
472
C6
6800/75
3234
253
251
4
254
5
472B
L2
L9
471B
6
FLEX CIRCUIT
1
2
X5
X6
SHIELDED
CABLE
251
7
CONTROL
RECTIFIER
-
20
+
3
1104
406 402
471
472
412 408 410
411 407
403
405
1103
401
4
P.C. BOARD CONNECTION DETAIL
5
L6
L7
SHIELDED
CABLE
J3
6
FAN
MOTOR
7
8
9
FAN
RE LAY
+
-
FAN
715
716
10
~
X5
X6
401
402
403
1
2
3
4
405
406
407
408
5
H1
H2
503
6
X3
J4
C1
C2
C3
B4
300A CHOPPER BOARD
7
H5 H2 H3 H4
H1
B1
B2
503A
B2
8
L1
CHOKE
B1
115V
B5
9
(SHOWN
CONNECTED
FOR 230V)
+STUD
901B
L1
L2
410
411
412
B5
901
10
11
12
X4
X1
C4
B6
B3
TP4
L1
L2
LINE
SWITCH
2520
H5
H3
RECONNECT PANEL
H4
H1
R2
903B
1
2
3
4
LEM
R1
C5
2400/100
502
503
TP6
W
B
H1
H1
C
O
N
T
R
O
L
J5
B6
2530
H4
G
H4
X2
MSP III BOARD
1
4
2
3
-STUD
GND
TP5
502
503A
TO + STUD
GEARBOX
4A
4
1
2
2
SE T
SE LECT
802 801
804 806
3411
1
2
3
4
E
D
B
2A
75
75A
76
3
SWITCH
3415
SWITCH
3417
F
C
FOOT
AMPTROL
AMPHENOL
833
604
607
903
4
A
76A
5
3411A
3411
3411A
3416
77
DIODE
BRIDGE
3414
3415
3416
3417
DUAL PROCEDURE
77A
TRIGGER
GAS
SOLENOID
6
J341
5
(VIEWEDFROMREAR)
TACH
7
3414
6
7
8
WIRE DRIVE
MOTOR
76A
8
4A
DISPLAY
P.C. BOARD
J6
834
E
G
B
J37
FLEX
9
SPOOL GUN
PUSH-PULL
AMPHENOL
F
D
C
2A
L8
1
2
3
4
75A
604
611
10
11
12
13
14
15
16
A
3218
3214
836
B
W
B
853
8111
PANEL ENCODERS
VOLTS/TRIM WFS/AMPS
L5
77A
851A
O
A
R
2
3
4
5
2B
L4
L3
2
3
2
1
3
2
1
615
SPOOL GUN/
PUSH-PULL
SWITCH
SHIELDED CABLE
J34
6
D
7
8
1
2
B
W
852
851
855A
9
SPI SPOOL
GUN BOARD
3
8511 858
857 8510
859
8512
1
2
3
4
5
6
7
8
855
77
10
4
3218
3214
5
6
FLEX
8514
76
846
J810
7
832 834 836
846
1102
8
3233
1101
846A
841:R
831 833 835
844:B
4
853
847:U
J7
8514
3234
9
10
11
12
13
14
15
16
75
1
2
8111
8115
LEADCOLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
4
2
4
1
3
1
1
1
1
10
9
10
9
2
3
4
5
6
7
8
9
W=WHITE
8
1
5
7
715
716
4
6
3
2
8
G=GREEN (W/YELLOWSTRIPE)
8
1
1
8
1
6
5
7
7
6
6
801
802
1
2
3
4
5
6
7
8
7
J86
12
6
10
9
16
6
14
5
5
CONNECTOR CAVITY NUMBER ING SEQUENCE
(VIEWED FROMCOMPONENTSIDE OF BOARD)
4
4
FEEDER BOARD
3
3
804
806
L2 THRU L9ARE RF CHOKES
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
2
J8
2
10
1
1
8115
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE
(VIEWED FROM LEAD SIDE OF RECEPTACLE)
1102 1104
1101 1103
901 903
3
6
9
2
5
8
1
4
7
1 2 3
4 5 6
7 8 9
9 PIN
J50
9 PIN
P50
A
G4511
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWER MIG 300
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - CODE 10958 AND 11000 ONLY
5 3 1 G 4
CHANGE DETAIL: VARIOUS CORRECTIONS.
ENGINEERING CONTROLLED
MANUFACTURER: No
ALL LED's
LIGHT
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
COLOR CODE
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
BRIEFLY
A DASH "-" SCROLLS
ALONG DISPLAY BOARD
(TAKES ABOUT 10 SECONDS)
1
1
3
6
4
8
1
2
B -
W -
R -
U -
BLACK
WHITE
RED
J83,J88
J2,J84
J81,J82
5
4
3
4
BLUE
1
8
LOCATED ON FRONT
OF MACHINE'S BASE
1
5
MACHINE DIS P LAYS
SETTINGS OF LAST
J1,J86
J85,J87
WE LD MODE OPE R ATION
MAIN
TRANSFORMER
10
16
9
6
H1
H2
LOCATED ON
MAC HI NE 'S B AS E
(STORAGE
H5 H2 H3 H4
H1
IF LAST MODE WAS CC
AMP LED ILLUMINATES
IF LAST MODE WAS CV
WFS AND VOLTAGE
IF LAST MODE WAS SYNERGIC
WFS AND TR IM
COMPARTMENT SIDE)
LOCATED ON TOP OF
MAIN T R ANS F OR ME R
(SHOWN
CONNECTED
FOR 230V)
L1
L2
OUTPUT
RECTIFIER
LED's ILLUMINATE WITH
WITH COR R E S PONDING VALUE.
RIGHT DISPLAY "OFF"
LED's ILLUMINATE WITH
LOCATED NEXT TO
MAIN TR ANS FOR ME R
(ON WIRE DRIVE SIDE)
OUTPUT
CHOKE
CORRESPONDING VALUES.
CORRESPONDING VALUES.
L1
L2
LINE
SWITCH
H5
H3
RECONNECT PANEL
H4
2520
H1
H1
CHOPPER P.C. BOARD
(SCHEMATIC M19792-1)
57 VAC
80 VDC
CURRENT
TRANSDUCER
R1
W
B
2400/100
-
H1
2530
H4
E
C
G
H4
115 VAC 30 VAC
G
LOCATED ON
CHOPPER BOARD
ASSEMBLY
X5 X6
X3 X4
121K
LOCATED AT
MAC HINE 'S BAS E
(WIRE DRIVE SIDE)
CONTROL RECTIFIER
PWM=20KHZ 12V
LOCATED ON
TRANSFORMER
BAFFLE
-
FAN
FAN STAYS ON FOR 5 MIN AFTER
LAST GUN TRIGGER (WHEN 2/4
IS CLOSED)
FOR ALL FLEX AND
SHIELDED CABLE
CR1
6 V
+ 42VDC
+
1
2
3
4
5
6
7
8
9
10
+15V
+5V
DIGITAL POWER
SUPPLY P.C. BOARD
(SCHEMATIC G3631)
FAN RELAY
LOCATED ON
TRANSFORMER
BAFFLE
6800/75
/SS
+15VDC CONTR OL BD SUPPLY
-15VDC CONTROL BD SUPPLY
+5VDC CONTR OL BD SUPPLY
CONTROL BD SUPPLY COMMON
CS1
CS2
CS3
MISO
SCK
MOSI
GRD
2J41
1J41
1J42
472
471
412
411
408
410
2J42
3J42
5J42
TOROID
LED2
RED
LED1
RED
TOROID
CHOPPER
SUPPLY
ALL 3 LE D'S ILLUMINATE
AT THERMAL TRIP.
COMMON
+20VDC
1J43
7J43
ILLUMINATED LED
431
437
SPI FLEX/SHIELDED
CABLE SUPPLY
INDICATES VOLTAGES ARE
BEING SUPPLIED TO J42
LOCATED ON
SECONDARY
WINDINGS
LOCATED ON
CHOPPER BOARD
HEATS INK
+5V
+15V
COMMON
SPI DISPLAY
L11757-1
3J43
6J43
12J43
SCHEMATIC: L11108
YELLOW
403
402
401
ILLUMINATED LED
INDICATES VOLTAGES ARE
BEING SUPPLIED TO J43
RS232 SUPPLY
+5V
COMMON
4J43
9J43
406
405
503A
CAN COMMUNICATION
SUPPLY
N.C.
FOR WELD FILE
DOWNLOADS
LOCATED ON TOP
OF P.C. BOARD
COMPARTMENT
N.C.
+5V
COMMON
RED
RED
RED
5J43
10J43
RED
1104
1103
LOCATED AT BOTTOM OF
P.C. BOARDCOMPARTMENT
PLACED AT A 45∫ ANGLE
ILLUMINATES WHEN
DISPLAYING WFS
ILLUMINATES WHEN
DISPLAYING AMPS
ILLUMINATES WHEN
DISPLAYING VOLTS
ILLUMINATES WHEN
DISPLAYING TR IM
R232
CONNECTOR
LOCATED ON DIVIDER
PANEL IN THE WIRE DRIVE
COMPARTMENT
+ 10VDC
COM
+ 10VDC
CONTROL
P.C. BOARD
(SCHEMATIC G3789)
CONTROLS THE
FUNCTIONALITY OF
THE MACHINE.
3J2
4J2
1J2
253
254
251
TOROID
DUAL E NCODE R PR E S E NT
ON CODE 10562 ONLY
LED1
GREEN
7 PIN
SPOOL GUN/PUSH-PULL
AMPTROL
FEEDHEAD
P.C. BOARD
(SCHEMATIC G3883)
TOROID
MOTOR
MOTOR
+
-
FOR MECHANICAL ENCODERS,
AVAILABLE ON CODE 10952 AND
ABOVE , R E FER TO J85 ON FEEDHEAD
P.C. BOARD. THE DISPLAY BOARD
CONNECTS DIRECTLY TO THE MSP3
OPTION PANEL.
1
2
1J83
2J83
3J83
4J83
831
832
833
834
R13
X2
R10
B
L11559-
2
R5 R4 R9 R3 R8 R6 C5
R
C6
C7
C2
C8
D1
R12 R11
LOCATED BEHIND THE
INSULATING WIRE DRIVE
PANEL. REMOVE THE
WIR E DR IVE ASSEMBLY
TO GAIN ACCESS.
2
3
4
5
6
7
20
A1
A2
GAS SOLENOID +
GAS SOLENOID -
PWM: PULSE WIDTH
MODUL AT ION
C4
TP
VOLTAGE BETWEEN
801 AND 806 VARIES
DEPENDING ON
CURRENT THROUGH
LEM 500A = -4V
CONTROLS THE WIRE
DRIVE FUNCTIONS AND
THE GAS SOLENOID.
B
A
+ 15VDC
-15VDC
+ 5VDC
COM
TP
FLEX
2
3
C9
PWMCONTROLLED
412
411
408
410
12J4
11J4
8J4
X1
6.5 VDC WHEN GAS
FLOWING COIL
ME AS UR E S 21 OHMS
12 VDC COIL
C3
R1
J36
C1
LOCATED ON
CASE BACK
J361
SPOOL GUN/PUSH-PULL MOTOR
0VDC @ 50 IN/MIN
DUAL
ENCODER
10J4
24VDC@ 700 IN/MIN
SPOOL GUN
P.C. BOARD
(SCHEMATIC G3997-1)
5K
CONTROLS THE SPEED
OF THE SPOOL /
B
W
ACCESS THIS CONNECTOR
BY REMOVING THE WIRE
DR IVE ASSE MBLY
TOROID
+ 5VDC
SPI SUPPLY +15VDC
COM
403
402
401
3J4
2J4
1J4
PUSH-PULL GUNS BY
READING THE
POTENTIOMETER.
MOT OR / G E AR BOX
TACH
5VDC TACH SUPPLY
TACH SIGNAL
2.6 VDC @ 50 IN/MIN
R
U
B
R
U
B
1
841
847
844
1J84
7J84
4J84
27.4 VDC @ 700 IN/MIN
8 SECOND AVERAGE CURRENT
LIMIT =3.5A
RS232 SUPPLY +5VDC
COM
2
406
405
6J4
5J4
MS P 3 BOAR D
(SCHEMATIC: L11612)
TACH COM
3
4
SHIELDED
CABLE
ME AS UR E B T O U
JUMPER ARE SO THE
CONTROL BOARD
RECOGNIZES
THAT IT IS IN A
PM300
ALLOWS THE SELECTION OF DIFFERENT WELD
MODE S AND PR OCE S S E S .
(LIMIT IS SOFTWARE SET)
120 Hz @ 50 IN/MIN
1.6 kHz@ 700 IN/MIN
4J6
10J6
604
LED2
2A 76A
4A 77A 75A
LOCATED ABOVE WIRE
DR IVE AS S E MBLY ON
CENTER PANEL
GUN TRIGGER SUPPLY
GUN TRIGGER INPUT
11J6
12J6
3214
3218
4J324
8J321
1J85
2J85
851
852
THIS LED WILL BE
BLINKING IF THERE IS
AN ER R OR
+ 15VDC
+5VDC
+0VDC
1J3
2J3
10J3
611
GREEN
LED5
CAN COMMUNICATION SUPPLY +5V
0V
TOROID
4J11
3J11
1J11
2J11
1104
1103
1101
1102
LED3
REMOTE
+15VDC
+5VDC
COMMON
GREEN
CAN COMMUNICATION
CAN COMMUNICATION
B
C
A
76
1J321
2J321
7J321
1J32
2J32
1J86
2J86
10J86
2J82
1J82
LED4
REMOTE
75
GREEN
LED6
REMOTE
77
SHIELDED CABLE
DIP SWITCHES
DIP SWITCHES
10J32
LOCATED IN LEFT SIDE OF
P.C. BOARDCOMPARTMENT
GREEN
SWITCHES MUST BE
IN OFF POSITION
SWITCHES MUST BE
IN OFF POSITION
TRIGGER
COMMON
+ 6VDC
COM
15J7
16J7
SELECT
SWITCH
SET
SWITCH
E
D
F
4
TRIGGER
2
3J321
6J321
3J324
4J324
3243
3243
3244
3J82
4J82
715
716
TO POWER FEEDHEAD BOARD +42VDC
GREEN
LED7
3244
GREEN LED's REMAIN
SOLIDGREEN
LOCATED TO THE RIGHT
OF WIRE DRIVE ASSEMBLY
ON CENTER PANEL
REDLED's ARE SOLID AT
POWER UP THEN BLANK
LOCATED AT BOTTOM OF
P.C. BOARDCOMPARTMENT
6 PIN FOOT AMPTROL
LOCATED ON DIVIDER
PANEL IN THE WIRE DRIVE
COMPARTMENT
RED
+15VDC
855
5J85
12J85
0V
8512
CONTROL P.C. BOARD LED LEGEND
LED1: +15V POWER TO CONTROL P.C. BOARD
LED2: -15V POWER TO CONTROL P.C. BOARD
LED3: +5V FOR SPI CABLE
LOCATED IN P.C. BOARD
COMPARTMENT
(LEFT FRONT SIDE)
SPOOL GUN/
PUSH-PULL
SWITCH
15VDC WHEN IN THE SPOOL GUN POSITION
0VDC WHEN IN THE PUSH-PULL POSITION
PANEL ENCODERS
LOCATED ON
CASEFRONT
LED4: +15V FOR SPI CABLE
WFS /AMPS
VOLTS/TRIM
LED5: +5V POWER TO CONTROL P.C. BOARD
LED6: +5V FOR RS232 CONNECTOR
LED7: A FATAL ERROR HAS OCCURED
LED8: +5V FOR CAN COMMUNICATION
LED9 AND LED10: ER R OR CODE . LED9 BLINKS ONCE
THEN LED10 BLINKS ERROR CODE.
COMPONENT VALUE UNITS:
LEAD COLOR CODE:
+
RECTIFIER BRIDGE
USED ONLY FOR
EXTERNAL DIODE
(USED FOR MOTOR
BRAKING)
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
3
2
1
3
1
2
CONNECTOR PIN NUMBERS:
EX. 12PIN CONNECTOR
LOCATED IN P.C. BOARD
COMPARTMENT
FOR CODE 10952
AND HIGHE R
1
6
LABELS:
COMMON
7
12
LATCH
FRAME GROUND
EARTH GROUND
VIEW OF CONNECTOR ON PC BOARD
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
DESIGN INFORMATION
REFERENCE:
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFE R E NT
FROMANACTUAL MACHINE.
EQUIPMENT TYPE:
SUBJECT:
PAGE _1__ OF ___
DOCUMENT
NUMBER :
1
POWER MIG 300
cstuble
DRAWN BY:
DOCUME NT
MAC HINE S C HE MAT IC
REVISION:
ENGINEER: J. SKERBEC
SCALE:
MAT E R I AL
NA
APPR OVAL
DATE:
PROJECT
G4315
CRM22115-EE
NUMBER :
B
3-26-2003
APPROVED:
Approve
NONE
DISPOSITION:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - CODE 11097 AND 11098 ONLY
2 5 1 G 4
CHANGE DETAIL: RELEASED A.01 FROMX.
ENGINEERING CONTROLLED
MANUFACTURER: No
ALL LED's
LIGHT
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
COLOR CODE
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
BRIEFLY
A DASH "-" SCROLLS
ALONG DISPLAY BOARD
(TAKES ABOUT 10 SECONDS)
1
1
3
6
4
8
1
2
B -
W -
R -
U -
BLACK
WHITE
RED
J83,J88
J2,J84
J81,J82
5
4
3
4
BLUE
1
8
LOCATED ON FRONT
OF MACHINE'S BASE
1
5
MACHINE DIS P LAYS
SETTINGS OF LAST
J1,J86
J85,J87
WE LD MODE OPE R ATION
MAIN
TRANSFORMER
10
16
9
6
H1
H2
LOCATED ON
MAC HI NE 'S B AS E
(STORAGE
H5 H2 H3 H4
H1
IF LAST MODE WAS CC
AMP LED ILLUMINATES
IF LAST MODE WAS CV
WFS AND VOLTAGE
IF LAST MODE WAS SYNERGIC
WFS AND TR IM
COMPARTMENT SIDE)
LOCATED ON TOP OF
MAIN T R ANS F OR ME R
(SHOWN
CONNECTED
FOR 230V)
L1
L2
INPUT
RECTIFIER
LED's ILLUMINATE WITH
WITH COR R E S PONDING VALUE.
RIGHT DISPLAY "OFF"
LED's ILLUMINATE WITH
LOCATED NEXT TO
MAIN TR ANS FOR ME R
(ON WIRE DRIVE SIDE)
OUTPUT
CHOKE
CORRESPONDING VALUES.
CORRESPONDING VALUES.
L1
L2
LINE
SWITCH
H5
H3
RECONNECT PANEL
H4
2520
H1
H1
CHOPPER P.C. BOARD
(SCHEMATIC M19792-1)
57 VAC
80 VDC
CURRENT
TRANSDUCER
R1
W
B
2400/100
-
H1
2530
H4
E
C
G
H4
115 VAC 30 VAC
G
LOCATED ON
CHOPPER BOARD
ASSEMBLY
X5 X6
X3 X4
121K
LOCATED AT
MAC HINE 'S BAS E
DIODE R ECTIFIER
(WIRE DRIVE SIDE)
PWM=20KHZ 12V
LOCATED ON
TRANSFORMER
BAFFLE
-
FAN
LOCATED AT BOTTOM OF
FAN STAYS ON FOR 5 MIN AFTER
LAST GUN TRIGGER (WHEN 2/4
IS CLOSED)
P.C. BOARDCOMPARTMENT
FOR ALL FLEX AND
SHIELDED CABLE
CR1
15 V
+ 42VDC
+
DIGITAL POWER
SUPPLY P.C. BOARD
(SCHEMATIC G3631)
1
2
3
4
5
6
7
8
9
10
+15V
+5V
FAN RELAY
LOCATED ON
TRANSFORMER
BAFFLE
6800/75
/SS
+15VDC CONTR OL BD SUPPLY
-15VDC CONTROL BD SUPPLY
+5VDC CONTR OL BD SUP PLY
CONTROL BD SUPPLY COMMON
CS1
CS2
CS3
MISO
SCK
MOSI
GRD
2J41
1J41
1J42
472
471
412
411
408
410
2J42
3J42
5J42
TOROID
LED2
RED
LED1
RED
TOROID
CHOPPER
ILLUMINATED LED
ALL 3 LE D'S ILLUMINATE
AT THERMAL TRIP.
SUPPLY
INDICATES VOLTAGES ARE
BEING SUPPLIED TO J42
COMMON
1J43
7J43
431
437
+20VDC
SPI FLEX/SHIELDED
CABLE SUPPLY
LOCATED ON
SECONDARY
WINDINGS
LOCATED ON
CHOPPER BOARD
HEATS INK
+5V
+15V
COMMON
ILLUMINATED LED
INDICATES VOLTAGES ARE
BEING SUPPLIED TO J43
SPI DISPLAY
L11757-1
3J43
6J43
12J43
SCHEMATIC: L11108
YELLOW
403
402
401
RS232 SUPPLY
+5V
COMMON
4J43
9J43
406
405
503A
CAN COMMUNICATION
SUPPLY
N.C.
FOR WELD FILE
DOWNLOADS
LOCATED ON TOP
OF P.C. BOARD
COMPARTMENT
N.C.
+5V
COMMON
RED
RED
RED
5J43
10J43
RED
1104
1103
1
2
ILLUMINATES WHEN
DISPLAYING WFS
ILLUMINATES WHEN
DISPLAYING AMPS
ILLUMINATES WHEN
DISPLAYING VOLTS
ILLUMINATES WHEN
DISPLAYING TR IM
R232
CONNECTOR
TOROID
LOCATED ON
CASE BACK
LOCATED IN LEFT SIDE OF
P.C. BOARDCOMPARTMENT
+ 10VDC
COM
+ 10VDC
PWMCONTROLLED
6.5 VDC WHEN GAS
FLOWING COIL
ME AS UR E S 21 OHMS
12 VDC COIL
CONTROL
P.C. BOARD
(SCHEMATIC G3789)
CONTROLS THE
FUNCTIONALITY OF
THE MACHINE.
3J2
4J2
1J2
253
254
251
MOTOR
MOTOR
GAS SOLENOID +
GAS SOLENOID -
+
-
LED1
GREEN
1J83
2J83
3J83
4J83
831:B
832:W
833
FEEDHEAD
P.C. BOARD
2
3
4
5
6
7
20
834
(SCHEMATIC G3883)
PWM: PULSE WIDTH
MODUL AT ION
VOLTAGE BETWEEN
801 AND 806 VARIES
DEPENDING ON
CURRENT THROUGH
LEM 500A = -4V
+ 15VDC
-15VDC
+ 5VDC
COM
412
411
408
410
12J4
11J4
8J4
FLEX
CONTROLS THE WIRE
DR IVE FUNCTIONS AND
THE GAS SOLENOID.
B
W
ACCESS THIS CONNECTOR
BY REMOVING THE WIRE
DR IVE ASSE MBLY
TOROID
10J4
MOTOR / G EAR BOX
TACH
5VDC TACH SUPPLY
TACH SIGNAL
TACH COM
2.6 VDC @ 50 IN/MIN
R
U
B
R
U
B
1
2
3
4
841
847:U
844:B
1J84
7J84
4J84
27.4 VDC @ 700 IN/MIN
8 SECOND AVERAGE CUR R ENT
LIMIT =3.5A
ME AS UR E B TO U (120 Hz @ 50IN/MIN, 1.6 kHz@ 700 IN/MIN)
+ 5VDC
SPI SUPPLY +15VDC
COM
403
402
401
3J4
2J4
1J4
(LIMIT IS SOFTWARE SET)
DUAL PR OCE DURE INPUT
853
3J85
2J85
4
2
LOCATED ABOVE WIRE
DRIVE ASSEMBLY ON
CENTER PANEL
RS232 SUPPLY +5VDC
COM
DUAL PR OCE DURE SUPPLY
2B
406
405
6J4
5J4
MS P 3 BOAR D
(SCHEMATIC: L11612)
3
SHIELDED
CABLE
GUN TRIGGER INPUT
852
JUMPER ARE SO THE
CONTROL BOARD
RECOGNIZES
THAT IT IS IN A
PM300
ALLOWS THE SELECTION OF DIFFERENT WELD
MODE S AND PR OCE S S E S .
GUN TRIGGER SUPPLY
851A
1
DIP S WITCHES
851
4
1J85
4J85
4J6
10J6
2
604
LED2
SWITCHES MUST BE
IN OFF POSITION
11J6
12J6
THIS LED WILL BE
BLINKING IF THERE IS
AN ER R OR
+ 15VDC
+5VDC
+0VDC
COMMON
3233
3J82
4J82
611
1J3
2J3
GREEN
TO POWER FEEDHEAD BOARD +42VDC
LED5
3234
CAN COMMUNICATION SUPPLY +5V
0V
4J11
3J11
1J11
2J11
1104
1103
1101
1102
10J3
LED3
GREEN
CAN COMMUNICATION
CAN COMMUNICATION
PANEL ENCODERS
WFS /AMPS
2J82
1J82
LED4
+15VDC
COMMON
GREEN
LED6
VOLTS/TRIM
5J85
12J85
855
8512
DIP SWITCHES
7 PIN AMPTROL
SPOOL/PUSH-PULL GUN
GREEN
LOCATED ON
CASEFRONT
RECTIFIER BRIDGE
SWITCHES MUST BE
IN OFF POSITION
15VDC WHEN IN THE SPOOL GUN
POSITION 0VDC WHE N IN THE
PUSH-PULL POSITION
+ 15VDC
COM
15J7
16J7
SELECT
SWITCH
SET
SWITCH
715
716
-
USED ONLY FOR
GREEN
LED7
3
2
1
3
1
2
SPOOL GUN/PUSH-PULL MOTOR
0VDC @ 50 IN/MIN
SPOOL GUN/
PUSH-PULL
SWITCH
835
836
5J83
EXTERNAL DIODE
(USED FOR MOTOR
BRAKING)
LOCATED ON
DIVIDE R
GREEN LED's REMAIN
SOLIDGREEN
LOCATED TO THE RIGHT OF WIRE
DR IVE ASSEMBLY ON CENTER PANEL
TOROID
24VDC@ 700 IN/MIN
REDLED's ARE SOLID AT
POWER UP THEN BLANK
PANEL IN THE
WIR E DR IVE
COMPARTMENT
6J83
5J88
B
A
RED
8J85
11J85
10J85
9J85
858
8511
8510
859
8115
5K
LOCATED IN P.C. BOARD
COMPARTMENT
LOCATED IN P.C. BOARD
COMPARTMENT
(LEFT FRONT SIDE)
CONTROL P.C. BOARD LED LEGEND
LED1: +15V POWER TO CONTROL P.C. BOARD
LED2: -15V POWER TO CONTROL P.C. BOARD
LED3: +5V FOR SPI CABLE
LED4: +15V FOR SPI CABLE
LED5: +5V POWER TO CONTROL P.C. BOARD
LED6: +5V FOR RS232 CONNECTOR
LED7: A FATAL ERROR HAS OCCURED
LED8: +5V FOR CAN COMMUNICATION
LED9 AND LED10: ERROR CODE. LED9 BLINKS ONCE
THEN LED10 BLINKS ERROR CODE.
7J85
857
E
F
C
D
G
8514
846
14J85
6J84
TO SPOOL/PUSH-PULL
GUN MOTOR DRIVE
SPOOL/PUSH-PULL GUN
BRAKE SIGNAL
(0 VOLT=MOTOR BRAKE)
COMPONENT VALUE UNITS:
LEAD COLOR CODE:
0-5V SIGNAL VARIES WITH
REMOTE POT WIPER
846A
8514
3214
3218
6J810
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
8115
8111
2J811
1J811
4J810
3J810
2J810
+40VDC SUPPLY FOR
4A
76A
77A 75A
3214
3218
SPOOL/PUSH-PULL GUN MOTOR
2A
REMOTE
76
5J810
8J810
1J810
CONNECTOR PIN NUMBERS:
EX. 12PIN CONNECTOR
76
75
77
B
C
A
REMOTE
75
REMOTE
77
LOCATED ON
DIVIDER
TRIGGER
D
E
2
TRIGGER
4
1
6
PANEL IN THE
WIR E DR IVE
COMPARTMENT
LABELS:
PROVIDES BRAKING OF THE
SPOOL/PUSH-PULL GUN
MOTOR AND CONDITIONS
THE SIGNAL FROM THE
POTENTIOMETER.
TOROID
LOCATED INSIDE THE
P.C. BOARD
COMPARTMENT
PLUGGED ONTO THE
FEEDHEAD BOARD.
F
COMMON
SPOOL GUN
P.C. BOARD
7
12
LATCH
6 PIN FOOT AMPTROL
FRAME GROUND
EARTH GROUND
(SCHEMATIC L12008-1)
VIEW OF CONNECTOR ON PC BOARD
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
DESIGN INFORMATION
CDIEKMANN
REFERENCE:
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFE R E NT
FROMANACTUAL MACHINE.
EQUIPMENT TYPE:
SUBJECT:
PAGE _1__ OF ___
DOCUMENT
NUMBER :
1
POWER MIG 300
DRAWN BY:
DOCUME NT
MAC HINE S C HE MAT IC
REVISION:
ENGINEER: JZUCKER
SCALE:
MAT E R I AL
NA
APPR OVAL
DATE:
PROJECT
G4512
CRM32923-B
Name?:Creation Date
NUMBER :
A
APPROVED:
-
NONE
DISPOSITION:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-8
G-8
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD #1 - CODE 10562 - 11098
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-9
G-9
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD #2 - CODE 10562 - 11098
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-10
G-10
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD #3 - CODE 10562 - 11098
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-11
G-11
ELECTRICAL DIAGRAMS
SCHEMATIC - DIGITAL CONTROL PC BOARD #4 - CODE 10562 - 11098
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-12
G-12
ELECTRICAL DIAGRAMS
SCHEMATIC - POWER SUPPLY PRINTED CIRCUIT BOARD - CODE 10562 - 11098
+5V
Machine Control Power Supply
R50
.13
J42
D18
3
1
2
6A
200V
+
t
D4
6A
200V
60V
LED2
10
T1
+5Volts, .750 Amp
C43
100
16V
C41
100
16V
C39
0.1
50V
T1
C12
33.2
33.2
10-55 VDC
Operation
.0015
2000V
332
3
Vref
1
10.0K
10.0K
10.0K
R9
11
12
D22
10.0
1.0A
30V
R60
10.0
D
S
+15Volts
Q1
21A
200V
G
R61
10.0
.750 Amp
D24
C13
1
200V
7
8
4
5
6
VCC
OUT
VFB
1
5
Vref
1
J41
J41
2
J42
D3
1A
600V
VREF
RT/CT
GND
D19
DZ8
18V
3W
Vfb1
OCI1
2
4
X8
1
DC Input (+)
1
IN
OUT
COMP
CS
3A
600V
CNY17-3
R10
R5
3
100K
100K
2
6
4
X5
Vfb1
ADJ
9
+
t
7
D21
1.0A
30V
C11
22
35V
C14
0.1
50V
C47
1.0
35V
R55
1.21K
.33W
R52
221K
T1
1.82K
T1
OV1
475
Machine Control
Shut Down
4
6
C7
0.1
50V
C45
150p
100V
C6
4.7
35V
R39
R12
5.62K
Capacitor
56.2K
C8
820p
50V
3W
0.05
C42
R13
C32
2700p
50V
10p
100V
10.0K
J41
3
1
J41
1
8
X1
GND
5
DC Input (-)
REF
TL431
6
C44
0.1
50V
C38
4.7
35V
C40
1.0
35V
-15Volts, .100Amp
T1
1.21K
.33W
5
J42
J42
8
ADJ
J42
2
IN
OUT
DZ1
24V
3W
6
X9
14
D8
1A
600V
gnd_mcps
T2
+5V
Operation
1
D25
1.00K
Undervoltage
C31
.0015
2000V
30-55 VDC
Detect
D2
1A
D23
5
1
<30VDC
600V
1.0A
30V
OCI2
CNY17-3
D10
X3
D
Q2
21A
200V
J42
4
6
2
J43
G
4
7
6
VCC
OUT
R32
15.0
6
S
IN
OUT
Vref
2
8
4
5
2
VREF
RT/CT
GND
VFB
D9
1A
600V
DZ2
27V
.5W
C49
.022
R34
221K
DZ7
18V
3W
1
COMP
CS
R31
75K
Vfb2
ADJ
3
3
C53
.1
R29
X4
C27
C23
1.0
35V
100K
C25
0.1
50V
OV2
C24
4.7
35V
C26
1
200V
1.21K
.33W
T2
12
150p
100V
D20
1.0A
30V
C52
150p
DZ3
27V
.5W
15Volts, .250Amps
SPI
gnd_mcps
C2
0.1
50V
C3
4.7
35V
R38
R28
5.62K
56.2K
C4
820p
50V
3W
0.05
Overvoltage
Shutdown
> 55 VDC
C28
10p
100V
249
J43
R40
3
+
t
D16
16A
200V
.13
60V
OV2
OV1
LED1
2
+5Volts, 3 Amps
SPI
D14
D17
C37
100
16V
C36
100
16V
C35
100
16V
C34
0.1
50V
T2
13
150
.33W
150
.33W
150
.33W
D13
Vref
2
332
DZ4
3.3V
3W
C33
4.7
35V
15
J43
D15
X7
5
IN
OUT
1A
4
600V
1
5
GND
J43
OCI3
CNY17-3
R17
C5
0.1
50V
C1
4.7
35V
C30
1.0
35V
+5Volts, .100 Amp
CAN
8
T2
11
150
.33W
+
t
D7
1A
2
6
4
.24
Vfb2
6
600V
J43
+20Volts
.200 Amps
Gate Drive
475K
R21
10
C21
C17
4.7
35V
C18
4.7
35V
T2
9
0.1
2.49K
.33W
50V
C46
150p
100V
J43
D12
2
1.82K
C16
R22
J43
R24
.24
2700p
50V
10.0K
7
J43
D1
+
t
D6
1A
X6
4
1
IN
OUT
7
600V
1A
600V
X2
8
5
+20Volts
.200 Amps
Gate Drive
GND
REF
TL431
6
C22
0.1
50V
C20
4.7
35V
C19
4.7
35V
T2
8
C9
0.1
50V
2.49K
.33W
C10
4.7
35V
C29
1.0
35V
+5Volts, .100 Amp
RS232
T2
10
150
.33W
J43
11
J43
J43
J43
9
1
12
FILENAME: G3631-2D2
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
LAST NO. USED
R-
C-
D-
CAPACITORS
RESISTORS
DIODES
=
MFD
(
.022/50V
UNLESS OTHERWISE SPECIFIED)
NOTES
:
LABELS
=
Ohms
(
1/4W UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
N.A. SINCE COMPONENTS OR CIRCUITRY ON
A
PRINTED CIRCUIT BOARD MAY CHANGE
=
1A, 400V
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
SUPPLY VOLTAGE NET
POWER SUPPLY SOURCE POINT
COMMON CONNECTION
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING
NUMBER.
A
COMMON CODE
FRAME CONNECTION
EARTH GROUND CONNECTION
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A.
UNLESS OTHERWISE SPECIFIED TOLERANCE
"X" INFO.
Chg. Sheet No.
6-2-2000A
DESIGN INFORMATION
REFERENCE:
MANUFACTURING TOLERANCE PER E2056
EQUIPMENT TYPE:
Di gi ta l S y s te ms
Schematic, Digital Power Supply
ON
ON
2
3
PLACE DECIMALS IS .02
PLACE DECIMALS IS .002
DRAWN BY: JP\TK
ON ALL ANGLES IS .5 OF
MATERIAL TOLERANCE ("
A
DEGREE
10-27-2000E
SUBJECT:
t
") TO AGREE
ENGINEER:
SUPERSEDING:
WITH PUBLISHED STANDARDS.
DATE:11- 30-98
DRAWING No.:
APPROVED:
SCALE:NONE
G 3631
DO NOT SCALE THIS DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-13
G-13
ELECTRICAL DIAGRAMS
SCHEMATIC - CHOPPER BOARD - CODE 10562 - 11098
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-14
G-14
ELECTRICAL DIAGRAMS
SCHEMATIC - MSP3 PC BOARD - CODE 10562 - 11098
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-15
G-15
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - MSP3 PANEL - CODE 10562 - 11098
ITEM
REQ'D PART No.
DESCRIPTION
LED SPACER
FLEX CIRCUIT
1
2
3
8
1
T15176-2
L11166-1
.01 OZ. E3539
ELECTRICAL INSULATING COMPOUND
GROUND SIDE
FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATIONS
C1,C2,C3,C4,C5,C6,C7,C8,C10 15
C11,C12,C13,C14,C15,C16
S16668-11
CAPACITOR,CEMO,0.1, 50V,10%
C9
1
1
1
1
8
S13490-104 CAPACITOR,TAEL,39,20V,10%
2
DISP1
S17395-9
S18248-10
S19365-8
T13657-6
LED,DISPLAY,7-SEGMENT,CC,4-DIGIT
CONNECTOR,MOLEX,MINI,PCB,10-PIN
CONNECTOR,PCB,MALE,RT-L,8-PIN
LED,T-1,RED,HLMP-K101
J34
J341
LED1,LED2,LED3,LED4,LED5
LED6,LED7,LED8
R1,R2,R12,R13,R14,R15,R16 16
R17,R18,R19,R20,R21,R22
R23,R24,R25
S19400-1001 RESISTOR,MF,1/4W,1.00K,1%
R3
1
6
1
1
2
1
1
1
2
1
S19400-2670 RESISTOR,MF,1/4W,267,1%
S19400-1212 RESISTOR,MF,1/4W,12.1K,1%
S19400-2002 RESISTOR,MF,1/4W,20.0K,1%
S19400-9091 RESISTOR,MF,1/4W,9.09K,1%
R4
R7
M19790-2
MSP OPTION
PANEL
C5
R4,R5,R6,R7,R8,R9
C4
R8
D
C1
J34
R10
R11
X1, X2
X3
R
X1
X2
C9
X3
S20496-1
S17900-28
S17900-8
S17900-26
S17900-10
S19869-2
IC,CMOS,DRIVER,DISPLAY,LED,CC,MCU
R16
R10
R17
R24
S1
LED
DISP
1
IC,CMOS,HEX,BUFFER,3-STATE,2-BIT,4-BI
IC,CMOS,INVERTER,SCHMITT,HEX,HC14A(SS
IC,CMOS,MUX,DAT,8-INPUT,HC151(SS)
IC,CMOS,REGISTER,SHFT,S-PI/SO,8-BIT(S
SWITCH,DIP,SPST,2-CIRCUITS
2
1
O
N
X4
C7
J341
X5
C16
C14
C6
C15
X6, X7
S1
R19
R18
R15
C11
C2
R21
R20
C12 C13
C10
R23
UNLESS OTHERWISE SPECIFIED:
CAPACITANCE = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
A
1
M19790-2
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 troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER MIG 300
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G-16
G-16
ELECTRICAL DIAGRAMS
SCHEMATIC - FEEDER PC BOARD BOARD - CODE 10562 - 11098 - SHEET 1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-17
G-17
ELECTRICAL DIAGRAMS
SCHEMATIC - FEEDER PC BOARD BOARD - CODE 10562 - 11098 - SHEET 2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-18
G-18
ELECTRICAL DIAGRAMS
SCHEMATIC - SPOOL GUN PC BOARD - CODE 10562 - 11098 - SHEET 1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-19
G-19
ELECTRICAL DIAGRAMS
SCHEMATIC - SPOOL GUN PC BOARD - CODE 10562 - 11098 - SHEET 2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-20
G-20
ELECTRICAL DIAGRAMS
SCHEMATIC - ENCODER PC BOARD - CODE 10562 ONLY
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-21
G-21
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - ENCODER PC BOARD - CODE 10562 ONLY
ITEM
R
EQ'D PART No.
L11166-1
.01 OZ E3539
S24951-4
DESCRIPTION
N.B.
1
2
3
1
FLEX CIRCUIT
N.B.
ELECTRICAL INSULATING COMPOUND
CPLD SOFTWARE
1
FOR ITEMS BELOW, REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATION
1.50
A1,A2
2
1
7
1
1
1
1
1
M17789-2
ENCODER,ROTARY,OPTICAL,61JY2049
CAPACITOR ,SMD,TANTALUM,47MF,20V,10%,S7343
CAPACITOR ,SMD,CER AMIC,0.1MF,50V,10%,X7R ,S0805
CAPACITOR ,PEMF,0.33,200V,10%
B
R10
R13
L11559-
C1
S25024-7SMT
S25020-3SMT
S13490-94
R
C6
2
X2
C2,C3,C4,C5,C6,C7,C8
R5 R4 R9 R3 R8 R6 C5
C7
C2
C8
D1
C9
R12 R11
A1
A2
D1
S25040-5SMT
S18248-10
S24020-4
DIODE,SMD,DUAL,0.200A,70V,UFR
J36
CONNECTOR,MOLEX,MINI,PCB,10-PIN
CONNECTOR ,MOLEX,MINI,PCB,4-PIN,TIN
C4
TP
J361
R1
S25001-2670SMT R ESISTOR ,SMD,267OHMS,1/4W,1206,1%,TR
TP
3
.75
0
2
R3,R4,R5,R6,R8,R9
10 S25000-1212SMT R ESISTOR ,SMD,METAL FILM,1/10W,12.1K,1%,S0805
C9
R10,R11,R12,R13
X1
R14
R15
R16
1
1
1
1
1
S25000-1501SMT RESISTOR ,SMD,METAL FILM,1/10W,1.50K,1%,S0805
S25000-28R 7SMT RESISTOR,SMD,METAL FILM,1/10W,28.7OHMS,1%,S0805
S25000-4750SMT RESISTOR ,SMD,METAL FILM,1/10W,475OHMS,1%,S0805
C3
R1
J36
C1
N.A. X1
N.A. X2
S25070-3SMT
S17900-8SMT
CPLD,PR OGR AMMABLE,XC9536,44-PIN,VQFP(SS)
IC,SMD,CMOS,INVER TER ,SCHMITT,HEX,HC14A(SS)
J361
.15
DUAL
ENCODER
0
4.85 5.00
N.B.
1
12-21-2001A
11559-2
L
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 troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER MIG 300
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G-22
G-22
ELECTRICAL DIAGRAMS
SCHEMATIC - DISPLAY PC BOARD - CODE 10562 - 11098
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWER MIG 300
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G-23
G-23
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - DISPLAY PC BOARD - CODE 10562 - 11098
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 troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
POWER MIG 300
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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 with us. Please include the
machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99
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