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Lincoln Electric SVM160-B User's Manual

1.
2. 5 2 D 2 15 1 m 10 o z REFERENCE FOR EXTERNAL POT olg 1 5 10 0k 5 REMOTE POT INTERFACE 05 amp took E 5VREF 01 975 FTPB 5 E 9 07 tr P HE xi 860 bsa x7
3. E 68LE9 JE 3 3 3 RE SHT 3 R10 R9 2 1 R10 1 5 089 775 gt TWT s i R16 e o I MISCO 6 171937 2761 72 86 89 109171 135144 25 45V 330pr 100 5V RISK LOV a Qu E cu cios C106 X24 cus _ 0120 15V 100 R18
4. c 6819 5VA R111 R110 25V 45V TOOK TTSK 2 EA 2 1 1 s 74 200V 1 o z aN Xm AD_DATALO 131 FESELRAME ux is S TZ D _ E Shook 5 40 47 BL 100K zx 25V 08015 AD_DATAIO 5 z l 040 pai AD DATAILI 3 9 oze V
5. 68169 15V 5V Ju 15V gt 12 SHT 13 9 gt gt 3 4 RS232 RXD 1 221K E VHCL4D da 014 RS232 TXD ird 18V d lax m IW X10 01 xao 01 a B 50V Bs 50V VHC14D 5 5 un VE VHCLUD VHCLUD p n GREEN 7 7 10 t gt SHT 134 asv m M v i 5 5VRS232 L 18V D63 5VRS
6. 68129 o 3m DATAIO 15 o gt DSP READY 3d peapy 9 gt SHT 2 E SHT 1 19 SHT 1 E 50 vccp w bis DSP REN 5V 5V 45V 45V 5 SHT 1 DUTPUT ON 72 ADCINO IOPAO wH i 5 13 ADCINL IOPAZ 519 03 05 3 sms 1 ps 21 03 25 77 SCK 78 130 E E Ve xlxlxlallala gt 1139 1 0139 1 0185 185 DATAI6 Tja mp SISE SIRIS amp Sm5S 150 141 184 DATAUI ADC
7. O o 2 2 82 d From Rectifier 2 2 15 1 gt 2 TOES AES cio 1 T gt st 10000 10000 R16 AIN 1 150V 150V ala 1 8 cei Al Al 2 071 562 VS1 VS2 105 P 081 V js 2 INPUT ourPur1 Sm ms Rectifier 50V 1w 4 6 9 Th 4 GND1 DUTPUT2 Jy 4451BN GND2 5 e lne X 10 0K zi 100 ie 63V L K 20 e R2 2 7 12 17 Output GND T 50V 50V 5W RL 100 CI C2 C4 To Choke R18 v R5 8 CT 1 21 GND 15 V R3 100 3L K Al 07 2 8 7_ 6 2 155 53 olo PWM CONTROL p a1 213 18 E 600V O16 INPUT OC 45 4 75K Fle 1A HCPL2601 41K E1
8. e MODES 52 8 5 JEN S JUMPER T 5 5 o gt Nee 5 FUNCTION 8 EI Em 9 9 NOT PRESENT OFF MSP 2 41495853 ay 5 amp cle eeESSPEESESESES present OFF MX 5 08 ser 0705965 9 NOT PRESENT ON ROBOTIC 6 O SELECT 54 al P 82r B E5 5 PRESENT ON FUTURE 7 558 0205 59 5 a TOOK 052 B2 J 2 PUSHBUTTON ys 4 816 u o 3882 L1 1 00K A Vj o O uu 2 524 mu R17 12g gt 25 200 7 T an J341 13 x5 S 6 R18 zi ET 140 8 1 00K lt 2341 og Ihe Z m ax 2 11 SS PL 26 2 tum ii MC
9. e REMOTE SWITCH INPUTS sy ARLLINK BICOLOR STATUS LED CONTROL p 254 MOTOR SUPPLY VOLTAGE MONITOR inh W 1845 MEN 2 Y L 20 RA E FRA HOT I MAN Nim TRIGGER 17 gt IW ane A 3 a5 856 AM CATHODE o Jik ms EIN _ 5 Tas jus i 57594 9 AREE gj 041 S iE uum n uz d TU 2 ALLG Rz 1 aLe e MA 45V S LEDs MTR SETUNIN OUT p 5 iN Ww 4 L g xs 1 12 07 17 5L 21 137 24 P gu ARC VOLTAGE FEEDBACK 5 DUAL gt 5 iu du TAILLED ERN 521 a ieu vet BBE gt os T gt 222 223 154 m m LH 5 e 37544 5733bh S UE En he STAT LEL REI IZ 4 Patt Vim gt iw iW SE n 1 b 022 023 ZB 7
10. oa 912 o gs olo 4 45 c MOTOR CIRCUIT SUPPLIES MOTOR DRIVER 5 5 usv it FTP2 15V A VM 1 Hv gt 2323 1 a 10 0K 5 10 0K 5 10 0K E 18A r3 2 2 1 93 a 441 200V 1 3 267 10 1 im 200 om ud pe 1 D 2 p 18V 55 13 a 3 Sm 3 ils 50 3638 8 1 a5 9010 160V RI R2 21 EI 55 wl 2 2 4 2 E RIS 200 ARCLINK 50V 50V E 20V 2 PEAK LIM 135 100 010 E E 338 g 5 MOTOR 1 i mls alt 5 4 8 xi x2 q 2 59 p 1 43110 4310 PwM_ouT SHT 9 2 E 08 B 03 B ke am 5 E E jax i n Ai a 3 1 03 zw 7 2 187 iN TU 32324 03 V 18 7 ARV lie loi 01 01 law olo 5o 912 o ols o o 15V 9 9 MOTOR CURRENT E 15 5 8 165
11. D 2 Liner Removal and Replacement D 3 POWER MIG 300 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O 2 99 gt elg EIS 2 oO 1 Return to Section TOC Return to Master TOC D 2 MAINTENANCE D 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill e 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 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 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 For instructions on replacing or changing drive roll see Wire Drive Rolls in
12. Section Parts 409 amp P202 C Series POWER 300 LINCOLN 9 TABLE OF CONTENTS p INSTALLATION SECTION 9 INSTALLATION EDEN Section A Technical 1 nnne nne sene 2 Safety A 3 Input Supply Connection Diagratm ee a 4 Cable INStallation 5 Return to Master Q 2 2 E Return to Master TOC POWER MIG 300 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 515 PEN 8 515 2 21 Return to Section TOC Return to Master TOC 2 INSTALLATION ae TECHNICAL SPECIFICATIONS POWER MIG 300 INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 230Amp Rated Output Input Current 300 Amp Rated Output 208 230 460 575 60 Hz 48 43 22 17 Amps 72 62 31 25 Amps RATED OUTPUT Input Voltage Duty Cycle Amps Volts at Rated Amperes 208 4096 300 Amps 32 Volts 230 460 575 6096 300 Amps 32 Volts 208 230 460 575 10096 230Amps 29 Volts OUTPUT Welding Current Range Continuous Maximum Open Circuit Voltage Wel
13. m be 0 TEST PROCEDURE 8 If excepted voltages are not present the Control Board may be faulty Do 09000000 00000 00 082522 Return to Section Return to Master TOC 1 Remove input power to the machine 9 Check the feedback voltage from the current 2 Remove the left case side of the machine transducer with the Power Mig set on Mode 1 or2 and the machine loaded to 250 amps 3 Remove the PC compartment door 10 Make the following voltage test From the table below 4 Locate plug 8 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 5 Connectthe main power to the machine may be faulty 6 Make the following voltage test From the table FROM LEAD TO LEAD EXPECTED VOLTAGE below Also see Table F 2 1 8 6 8 7 Carefully insert the meter probes into the back of each Molex plug pin cavity E olg iz 8 5 5 ply aja 12 If for any reason the machine cannot be loaded to ees ear 250 amps Table 2 5 5 what feedback volt FROM LEAD LEAD EXPECTED VOLTAGE age is produced at various current loads 802 806 15 VDC 2 8 8 Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 5 Return to Secti
14. 401 lt 1 lt 402 lt 2 lt 403 lt 3 lt 405 lt 5 lt M 503 406 6 4 T 503 1 408 8 B5 CHOKE 4STUD X 9 410 10 411 lt 11 lt 412 lt 12 gt 2 gt H1 8 1 gt amp 9 8 7 6 Be ol aa A SHOWN CONNECTED FOR 230 12 RECONNECT PANEL 502 2 lt 503 lt 4 STUD 14 cs W 2400 100 B6 Return to Section TOC Return to Master TOC 802 J 300A CHOPPER BOARD i 525 lo eerie SHIELDED FLEX 604 lt 10 CABLE T C 611 lt lt lt 12 BRIDGE 11 ENCODER MEE lt T rooxdzon SET VIEWED FROM SWITCH r 345 I 4 3411 344 SPOOL PUSH PULL 2 5 Br SHIELDED CABLE ANPHENOL 3214 13 BOARD 14 lt 2361 615 lt 15 lt cro Se 1 Kie GUN TRIGGER gt L5 GAS LOCATED ON SOLENOID LOCATED ON 4 5 6 lt 7 lt lt se lt 9 7 d41 026
15. MAIN TRANSFORMER Hf LOCATED ON H5 H2 H3 H4 H1 MAGLINE S BASE COMPARTMENT SIDE CONNEC OUTPUT H 12 ON WIRE DRIVE SIDE SWITCH 3 RECONNECT PANEL oH 2 21 i 2520 a W T 2 57 gt 80 VDC Es RI as ae 2400 100 B H1 3 2530 6 0 H4 415 30 VAC LOCATED ON CHOPPER BOARD p X6 ASSEMBLY CONTROL RECTIFIER 3 LN M LOCATED ON TRANSFORMER PROCEDURE 5 Test for correct input voltage between L1 lead at the LINE SWITCH to L2 Voltage tested will vary A WARNING depending on the input voltage connection See The ON OFF POWER SWITCH will be hot during these tests NOTE Secondary voltages will vary proportionately with the primary input voltage 1 Disconnect the main input power supply to the machine 2 Perform the Case Cover Removal procedure 3 Remove the tool tray with a 5 16 in nut driver 3 screws TEST INPUT VOLTAGE TO THE MAIN TRANS FORMER PRIMARY WINDING 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 Wiring diagram for test point locations f the voltage is incorrect check for loose or broken leads between the reconnect panel and the ON OFF POWER SWITCH Also testthe ON OFF POWER SWITCH for proper operation f the voltage is correct check the same v
16. 42 c BOARD FLOWING COIL 126 im M44 SCHEMATIC 63789 MESURES ZTOHMS FEEDHEAD CONTROLS THE 12VDC COIL BOARD GREEN FUNCTIONALITY 11 1111 THE MACHINE SCHEMATIC 63883 VOLTAGE BETWEEN ee MODULA 801 AND 806 VARIES ACCESS THIS CONNECTOR E DEPENDING ON BY REMOVING THE WIRE THE GAS SOLENOID CURRENT THROUGH MOTOR GEARBOX TACH DRIVE ASSEMBLY 1 4 26VDC R svc Tach SUPLY Y 274VDC 700 INMN 0 __TACHSIGNAL I 85 AVERAGE CURRENT B A Ho ff HMT 35A MEASURE B TOU 120 SOINMIN 1 6 kHz 700 INMIN E LIMIT SOFTWARE SE 40 34 lt m SS 403 Mec DUAL PROCEDURE INPUT _ 3185 tt ec VARIABLE VOLTAGE FEEBACK 15 LEMSUPPLY 80 804 ILLUMINATES WHEN ILLUMINATES WHEN ILLUMINATES WHEN ILLUMINATES WHEN DISPLAYING WFS DISPLAYING 5 DISPLAYING VOLTS DISPLAYING TRIM gt 2 4 18 801 6 LOCATED ABOVE WIRE DRIVE ASSENBLY ON DUAL PROCEDURE SUPPLY Beas 6 NSP3BORRD CENTER PANEL 28 INPUT 2185 45 lt 54 lt SCHEMATIC 111612 JUMPER ARE SO THE ALLOWS THE SELECTION OF DIFFERENT amp MODES AND PROCESSES SWITCHES MUST BE 106 lt 5 4 45 THAT IT IS NA COMON 2255 INOFF POSITION 16 lt THIS LED WILL GUN TRIGGER SUP
17. aw P PRA 57 8 9 5 POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC 5 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE A 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 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 Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF
18. E E olg iz 8 e 5 5 ply Return to Section Return to Master TOC F 47 F 47 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT continued REMOVAL PROCEDURE 5 Remove gun 6 Remove work lead from output stud CASE FRONT ASSEMBLY REMOVAL ELECTRIC SHOCK can kill 7 Remove the case front assembly as follows High voltage is present when input power is applied to Using a phillips head screwdriver remove the 2 the machine screws holding the line switch to the case front b Using a 5 16 in nutdriver remove 10 screws hold NOTE Cut cable ties as needed to improve access ing the case front to the to the machine base and center assembly PREPARATION c Lift the case front upward and forward slightly then disconnect plug 34 from the MSP3 mode select 1 Disconnect main input power from the machine panel The case front assembly can now be removed See Figure F 13 2 Remove the case side panels using a 3 8 in nut driver Perform the Chopper Board Capacitor Discharge Remove the case top using a 3 8 in nutdriver POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo 512 2 5 Return to Section Return to Master TOC F 48 F 48 TROUBLESHOOTING amp
19. shy E aad A Eze z ue SEN VIN Mc ues RLL gt A POSSTSIN xL 7 2754 47K AU gt E PISTIN EW p 2L B_POSSTSIN 22 sur iL osa gt THRESH p LN e i al rynt Ea DN Vim MOTOA CONTROL CURRENT SENSNO ACO i 14 AV 7 5 4 TEX CURRENT FEEDBALK 1083 e 3 lt 1 10 AES je ZAV 4 14 72 L xis 5 Le gt LOCAL NATS li T 1 T m E BT w le 204 244 2k LDLAL POT INPUT x E fiw En E si VIN ss 2n Ew m HW za on UB Pea 74 4 EM TIT Tp Ty Tav SW 4 i abl S o gt o oo lt s a EX mV V n H RT a PIKER SARE E T asa 8 TPUT CONTROL L sn i DSA O12 asv im St CT namiz 45 5 INPUT SUPPLY UNDER VOLTAGE DETECT A ES H EOD S SOUR o WILL TURN OFF MOTDA FETS Bl oe wein 3 Pu DIESE WHILE INPUT VOLTAGE 15 BELOW 20V Sha nem 1 m mus zum 0 4 v 124 SUPPLY LH MV a lt a 54V EUH jk E A E xu S MER GHTDW LIN 5 5 Rit gt au CONTACT OR 2 EIL 7 1 FERES 2x GAS SOLEN
20. _ DIGITAL POWER SUPPLY BOARD C6 6800 75 Return to Section TOC Return to Master TOC RECTIFIER SPOOL GUN BOARD SHIELDED CABLE SHIELDED CABLE P C BOARD CONNECTION DETAIL L1 CONNECTED FOR 230V LINE SWITCH Return to Section TOC Return to Master TOC GEARBOX DISPLAY WIRE 9 137 FLEX DRIVE BOARD Sava n j TRIGGER PANEL ENCODERS VOLTS TRIM 5 5 REAR 321 32 3 SPOOL GUN OUO PUSH PULL AOX Y SHIELDED CABLE ANPHENOL 8 H GAS SOLENOID 0 8511 858 857 8510 859 ojo O10 E 2 a 23 e 5 5 ply ajo LEAD COLOR CODE B BLACK OR GRAY R RED OR PINK WHITE G GREEN WYELLOW STRIPE 1 8 1 9 16 CONNECTOR CAVITY NUMBERING SEQUENCE Jl l l l VIEWED FROM CONVPONENT SIDE OF BOARD 2224244 L2 THRU L9 ARE RF CHOKES ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR I PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE 1101 3244 1102 1104 1102 3243 VIEWED FROM LEAD SIDE OF RECEPTACLE 1101 1103 SHIELDED CABLE ola TEP lool doo loo loo ole 53 5 5 64305 Return to Section Return to Master TOC 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 th
21. Return to Section Return to Master TOC F 9 F 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The arc is unstable and or hunt ing Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Check for worn or melted contact tip Check for loose or faulty connec tions on the work and electrode cables Make sure electrode polarity or welding process being used is correct Check for rusty or dirty wire Make sure machine settings are correct for process being used shielding gas wire type wire size RECOMMENDED COURSE OF ACTION 1 Check for loose connections at the output terminals the chokes and all heavy current carrying leads See the Machine Diagram 2 Make sure that the transformer secondary leads are securely connected to the Output Rectifier assembly 3 Check the Output Voltage If waveforms are not correct Perform the Rectifier Assembly Tests 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 have porosity with electrode stub bing into plate Make sure the weld procedure and electrode polarity is correct for the process being used Welding voltage may be too low for wire feed speed being used
22. ___ 11000182128 mre SHT 4 595 R W s 24 VHCL40 MN CNT 8 BLOCK 2 9 qu 2 27 s 51 HT OUTPUT ON 50 CSI FAULT INT 12 23 CRYSTAL DSHT 4 gt SHT amp pATAD ISI 24 RUE EE 1 01381 yi 1 01382 51 sat 24 TEX P SHT 3 ROC 13 1y01481 V 01482 22 QUTPUT DN S sur 4 lt 3 PWRDN_INT 18 1 015 1 1 015 2 21 SOFTST C MN QUT 16 XC9536 1 016 2 29 DISABLE 4S5 1 SPLLATCH7 18 44 SHT 4 1 01781 1 01782 L C6 28 06 172 C69 CLK 8 43 11 pi 820pF 51 820pF sav 820pF AS 4700pF SHT 2 1 0 6 1 TCK 3 50V 1 28 50V 50 50V wd orit Toi 2 4 a 3 scc 1 2 n 6 Vee GENERAL INFORMATION LAST USED 1 SHT 4 1 0 GCK3 100 219 C67 anu C99 f HTA 36 orsi qms 19 16 A x17 01 01 x27 Au X25 01 ELECTRICAL SYMBOLS PER E1537 R 267 X 33 L 1 00 4 34 5V 50 xtos3s 50V 50 12816 2071 50 rezgrgoo 50 Tsoy CAPACITORS MFD 022 50 UNLESS OTHERWISE SPECIFIED 0 20 Y 1 LED 10 lt e mp ors 7 E RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 5 02 4 S 1 7 2 ES FILTER CAPACITOR VOLTAGE MONITORING al 0 GSR i 10 0K T 77 ra 10 DIODES 14 400 UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET o 02 J5 POWER SUPPLY SOURCE POINT 8 fS gt 2 R2 y INT 1 3PH 275 100K COMMON CONNECTION
23. current 5 5 GIW S oiw DETECTOR E fiso 01W RIO R13 H o 5 100 PEAK LIM 4 2 Re 55 1 100K Es ai 400V 1 0 17 3 5 ve p 3010 2 AMP AVERAGE LIMIT 2 6 22 2220 70 54 2900 Br AVE CURRENT 21 38 8 221 DETECTOR 01 L az 22 2v Vv GSPI 912 o Oo 2 olo 5 5 Siz Ld SV UNUSED PINS 3 3 ha 3321 Vet Vad ERA 507 ns GENERAL INFORMATION CAST WO USED e 7 2 ELECTRICAL SYMBOLS PER 1537 CAPACITORS MFO 022 50V UNLESS OTHERWISE SPECIFIED T RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS gt DIODES 1A400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 57 COMMON CONNECTION D 777 FRAME CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO Gl c AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF LINCOLN ELECTRIC CONNECTION o z SINCE COMPONENTS OR CIRCUITRY ON PRINTED Ch ge Sht No THE LINCOLN ELECTRIC UE COMMON CONTROLS IRCUIT BOARD MAY CHANGE WITHOUT AFFECTING BOARD MAY CHANGE WITHOUT AFFECTING CLEVELAND OHIO U S A SCHEMATIC SPI SPOOL GUN PCB 9 THIS DIAGRAM MAY NOT SHOW THE EXACT p
24. 5 5 AV 14510 513 4 145 CINN E Losrens NDILLO3NND2 ONNOYO 1 S NOLLOSNNOO AA INIOd 33 008 13N 391304 Adans W 519991 70079071 3140 3 031310345 3SIMH3HlO 53730 AO0t VI 530010 9031 47039 SSIMYSHLO SS37NQ Mf T 140 540151534 SUBVONVIS CSHSITENd TO 33499 OL J 32 983101 19131984 33940 Y 304 FSI STIONY TIY NO 200 FSI S WATO3O IVT NO ZO FSI STATIG 39414 2 3887 3 533 5371 5310 NO 2 3101 03119395 3SIMY3H1O SSIINN 3NON ESN OIHO 702 531443313 SHL 502 215193713 N IOONTT 3H 30 NOISSINY3d 55844 3 JHL LNOHLIM 5 035070510 38 01 LON SI ONY 02 21812313 NIOONIT SH 8 NINAO NOLLYHHOJNI AHY 13THdDHd SNIV INGO 13365 STHL perry 3 UE SOTTTT JAVN3 TLES AESSHN 3002 9 51081405 30 ABLITIOHE HO S1N3NOdIDO 129 3 IHL MOHS LON SIH CHVOS 3124802 V 30 ALTTIGV39NUHOUSINI IHL 9NLL23 449 100HLIM AVA 08409 LINSYIS Q31NT4d V NO AHLITIQHIO HO SIN3NOdKOO JONTIS SALON 031917395 3SIMHJHIO SSIMNN 05 220 044 540129492 ON 15971 LEGI3 334 5108845 791419379 NOLLVIASU NI 1944 39 THERMAL 8 THERMAL LEDS aloLcidLeifigini lt m in
25. oe TUMOR mie 200 ous Calibration settings 4 Rotate the output control knob until the dis play reads cur cAL POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo e iz g 2 5 Return to Section Return to Master TOC TROUBLESHOOTING amp REPAIR VOLTAGE amp CURRENT CALIBRATION PROCEDURE continued CALIBRATION CHECK CODES 10952 AND UP 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 1 Toggle and hold the mode select switch in the up position 2 Turn on the Power Mig 300 3 Once the display reads Pres Spin release the mode select switch Rotate the output knob until the display reads ALL nodE 4 Toggle the Mode Select switch once and wait for the machine to reset then toggle the MODE SET switch until the 5 panel reads 200 Disengage the idler arm on the wire drive so no wire will feed 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 6 Using the test meters note the output voltage and current 7 The Power Mig 300 voltmeter must match the test meter reading to w
26. DATABI o SHT 4 846 us NC CUN 10 c90 ADDRI6 20 15 po B8 DATAL4 M 4 40V sm i r3 ADDRITI 19 46 pos 0 DATAISI 5 1 lt 2 lt 84 vonsyN yec B ADDRIBI 1845 Doe 2 DATAI6 10 0K in E hen 1 F 4 416 89 EXTAL CLKOUT 90 CLK CLK gt sat ADDRI9 8 AB 007 DATALTI 100V 70 per ROLL 24 lt 8 140 TSB ADDRI101 7 Bo DATAIBI 02A thysi 52 8 XTAL TSBUOT 9 3 30v 30v 1L RES 92 05041 59 ADDRILI 6 5 82 91 2 INPUT output 7 J6 5 009 Kk n 1 US ADDRIL2I EN paio B DATAILO GNO1 OUTPUT2 123 lt 8 152 Hous L C 26 TSC 05743 ADDRIL3I Bn TE28F800 B6 DATAILL 44SIBM GND2 3 TRO AR 19 25 91 10 gt 15 gt 12 0011 3 E sov eav sov 3ov 5 lt sg EREE 94 BERR 50 7 Ni ADDRILA A13 00129 E 05178 5 2 t 00131 DATAIL3I 2 02 775 13 JL n 79 103 R W AN ADDRI161 tais DATA 141 Srl FANACONTROL per id o7 M SHT 4 11 H5 4816 0015 5 DATARISI ojo TIK 2 SHT FPGA DONE 113 TSART ADORNS _____ 40V 112 AVEC A2 A 00812 ADDRI19 16 18 RMC 111 ADDRI3I CSB 28 1 2 SHT 4 E A 032 FET B sir i AS 106 2 ADDRIGI R W
27. THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC THE INFORMATION ON THIS REFERENCE EQUIPMENT TYPE POWER 300 PRINT IS FOR REFERENCE DOCUMENT ONLY COMPONENTS AND SUBJECT MACHINE SCHEMATIC CIRCUTRY MAY BE DIFFERENT m FROMAN ACTUAL Me iow NA 3 262003 PROJECT CRM22115 EE SOLID EDGE EN 170 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER MIG 300 e ELECTRICAL DIAGRAMS iai SCHEMATIC COMPLETE MACHINE CODE 11097 AND 11098 ONLY ENGINEERING CONTROLLED CHANGE DETAIL RELEASED A 01 FROMX MANUFACTURER No M GENERAL INFORMATION BRIEFLY CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD ELECTRICAL SYMBOLS PER E1537 ADASH gt SCROLLS COLOR CODE ALONG DISPLAY BOARD B BLACK AKES ABOUT 10 SECONDS w WHITE R RED LOCATED ON FRONT WACHRE DISPUAYS U BLUE MACHINE S BASE SETTINGS OF LAS 2080666 MAIN TRANSFORMER 5 LOCATEDON MACHINE S BASE STORAGE COMPARTMENT SIDE IF LAST MODE WAS IF LAST MODE WAS CV IF LAST MODE WAS SYNERGIC AVP LED ILLUMINATES WFS AND VOLTAGE WES AND TRIM WITH CORRESPONDING VALUE
28. m 18 ga 140 17 140 1 5 110 1 5 110 1 5 100 2 5 100 2 5 110 2 0 110 2 0 x 2 8 16 190 2 0 190 2 0 125 2 0 125 2 0 125 3 0 125 3 0 140 2 5 130 2 7 z J 14 400 2 0 400 2 5 260 3 0 260 3 0 160 2 3 160 2 3 160 3 8 160 3 5 210 3 0 190 3 5 O lt gt m 5 12 330 5 0 330 4 5 230 3 5 230 3 5 200 5 0 200 4 5 27015 0 230 6 0 5 10 ga 500 7 0 500 7 0 300 6 0 300 6 0 24016 5 24017 0 325 6 5 300 7 0 u D z 3 16 570 9 0 600 7 8 400 7 5 400 7 0 9 14 700 9 1 700 8 5 olo Not Not Recommended E S COMMENTS below 400 below 400 5 ajo POWER MIG 300 LINCOLN 5 14 5 POWER MIG 300 LINCOLN B 14 901 Je1Se N 901 Je1Se N uunjeH 901 Je1Se N 901 Je1Se N DOL 5 DOL uonoeg 0 DOL uonoeg 0 DOL 5 Return to Master Return to Master TOC Q 2 2 E Return to Master TOC TABLE OF CONTENTS ACCESSORIES 0 0 0 Section PIV a 2 Push Pull Feeding Connection Adapter C 3 POWER MIG 300 LINCOLN 5 Return to Section TOC Return to Master TO
29. 01617318 10 2 5 5 m 3b Lrc 5723 X d sulle d 5 1 O 2 OZI IEY L zu la ESPEN SE DATA_OUT G 8 BANK gszur5z as w OJO 5 BANK FANE LEDL LED2 LED3 LEDA Leos LEDe LED7 LEDB gt 98 5 5296 gt gt 16 Ay AT AT gt lt 6555 25 S o 121K HC368A LI 27 DEBELE a qm 9 85 3 USADOS i y DATALIN AH 259 P gt 6 o 5 8 5 c 9EESSE 1 Rx C gt n an 5 2 V 14489 D 2 SE GSPI 5 1 515 FE 5 20 o 2 19 7 H aa O 6 5521 HC368A stk R9 HCLL xi 5 p 1 155 1 GSPI 22 Qu 5 E LOGIC TABLE BOARD 1D 0000100 olo 8 INPUTS OUTPUTS _ 5 Y 5 eje QOO Es ta SS PL XL X3 Pin 11 XI SS PL X2 EN MISO pul 14 16 16 16 3 16 3 Vcc Vcc Vcc Vdd Vcc Vdd x H x H 7 9 10 c5 C6 2 L r4 cz o Ri X4 04 5 01 X6 2501 x7 1 1 04 x3 0 2 04 H 7 n 50V c 50V 50V 50V 50V 50V g TO HC151 HC165 HC165 HC368A 30V SI 2 gt 95 gt GND GND GND Vss GND Vss 25 7 8 8 8 8 Li 29 H L SA olg ae 19 2234
30. Gas DC Input C Overvoltage Shutdown gt 55 VDC on on lt gt E x e E Lo Tw Sex Am E 15 E E Vow E Operation 30 55 VDC 4 H F fav Tah lt x cas 3 inv e x Sop 5Volts 100 Amp CAN E 5Volts 100 Amp RS232 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Machine Control Power Supply DE 5 5 A 5Volts 750 Amp p Y gt gt ux E 15Volts 250Amps 20Volts 200 Amps Gate Drive T NOTES NA SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE NTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMER gt gt 20Volts 200 Amps Gate Drive 5Volts 3 Amps FILENAME G3631 2D2 GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 CAPACITORS 0220500 _ UNLESS OTHERWISE SPECIFIED RESISTORS Ohms UNLESS OTHERWISE SPECIFIED DIODES 1A40V UNLESS OTHERWISE SPECIFIE
31. Return to Section Return to Master TOC E 5 THEORY OF OPERATION FIGURE E 5 WELD CONTROL BOARD E 5 MAIN OUTPUT CHOPPER POS TRANSFORMER RECTIFIER ASSEMBLY OUTPUT OUTPUT CHOKE TERMINAL CURRENT TRANSDUCER RECONNECT PANEL OUTPUT EE CURRENT TERMINAL EINE POWER ie VOLTAGE PWM DIODE CONTROL RECTIFIER 15 15 5 VDC IGBT DRIVE CHOPPER FAN rore WELD CONTROL BOARD CONNECTOR 40 FROMWELD VDC CONTROL BOARD TO FAN RELAY SHIELDED CABLE AND SPI COMMUNICATIONS FOOT AMPTROL OR REMOTE 6 PIN AMPHENOL ENCODER BOARD Below code 10900 SPOOL GUN PUSH PULL SWITCH 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 LINCOLN 5 6 6 THEORY OF OPERATION FIGURE E 6 WIRE DRIVE MOTOR AND FEEDBACK MAIN OUTPUT CHOPPER POS TRANSFORMER RECTIFIER ASSEMBLY OUTPUT GUN TERMINAL OEN CURRENT TR
32. i p 6 h AS 85 R240 R264 5 100 LES 332 7146 fs n 8 HC245 hz lu B7 R226 R265 6 M 100 332 R227 R266 y 014 100 332 n R267 8 1001 8220 332 X 12 21 1 a EE GENERAL INFORMATION LAST No USED 11 7 O O c47 c97 C96 c98 C100 275 275 ELECTRICAL SYMBOLS PER 1537 7T 10 ARN 10 01 01 01 VHC14D 045 C130 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 35 35v 50 50v 50v 51V uu RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 26 53 78 105 130 156 183 208 60 2 1321 8762 93 103 121 84 bo 1 24 5 DIODES 1A 400V UNLESS OTHERWISE SPECIFIED A SUPPLY VOLTAGE NET Vet 3 X18 X22 10 SUPPLY SOURCE POINT 0 208 TMS320F 240 ai 57 CONNECTION Ole 1 1325 38 51 66 79 91103118 131143158170 182 195 31420 29 46 59 61 71 92 104 113 120 87 A FILENAME 63789 10 Go FRAME CONNECTION 9 gt 79 16 c75 THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO EARTH GROUND CONNECTION M Ef 01 01 04 AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF LINCOLN ELECTRIC 50V 50V 50V 50V 50V 5 EQUIP 9 9 UNLESS OTHERWISE SPECIFIED TOLERANCE Ch ge Sht No INFO THE LINCOLN ELECTRIC CO INVERTER WELDERS vi ae 62 290 CLEVELAND OHIO U
33. Using slot or phillips head screw driver dis 2 Install the fan blade and tighten the fan blade connect the white lead at the fan relay See clamp Ensure the fan is in the same position on Figure F 16 the shaft as it was prior to removal Spin the fan to be sure itis free to rotate 5 Remove the fan blade Note the position of the fan on the shaft for reassembly 3 Connect 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 Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 5 52 52 TROUBLESHOOTING amp REPAIR VOLTAGE amp CURRENT CALIBRATION PROCEDURE WARNING Return to Section TOC Return to Master TOC 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 DE
34. 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 J 84 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 1 5 to 3 5 VDC If the 1 5 to 3 5 VDC is not present 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 If the leads are okay the tachometer circuit may be faulty replace the tach Sensor POWER MIG 300 LINCOLN 26 26 TROUBLESHOOTING amp REPAIR ENCODER PC BOARD TEST FOR CODES ABOVE 10562 WARNING Return to Section TOC Return to Master TOC 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 unders
35. 8 e 5 5 1 OE LE Do 19 0 Di 18 17 DATAQD Es x 16 8 03 De 5 DATAG D5 74 573 DATAG D6 13 6 07 12 7 10 287 00 th 287 TDI lt RESET 20 Ve GENERAL INFORMATION 1 x32 ELECTRICAL SYMBOLS PER E1537 2 CAPACITORS MFD 022 50V UNLESS OTHER Tene 1 A RESISTORS Ohms 1 44 UNLESS OTHERWISE SPECIFIED LABELS 1 27 16 im 6 DIODES 1A400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET POWER SUPPLY SOURCE POINT 5 3219 57 COMMON CONN VoD 7H FRAME VSTBY L EARTH GROUND CONNECTION 18 X30 5267 MC68376 VDDSYN 28 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC MAY NOT DUPLICATED COMMUNICATED E 288 2 ors 101109121 134 141 149 PROPRIETARY amp CONFIDENTIAL TO OTHER PARTI IR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC KEYING PLUG 2 T RY x SINCE COMPONENTS OR CIRCUITRY ONA REFERENCE EQUIPMENT TYPE COMMON DIGITAL CONTROLS PAGE 01 OF 02 WITHOUT AFFECTING THE INTERCHANGE DOCUMENT ABILITY OF BOARD THIS BILITY OF
36. 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 10 Connect fan lead X4 to fan relay terminal 1 and fan lead X3 at its in line connector at the fan motor 11 Install the case front assembly Connect plug 34 and mount the line switch 12 Install new cable ties as needed 13 Install the case sides and top POWER MIG 300 LINCOLN 5 49 POWER MIG 300 LINCOLN 5 REPLACEMENT continued FIGURE F 15 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND F 49 901 491590 0 Winey 901 Je1Se A 901 J91Se N 01 901 J91Se N 01 DOL uonoes uumeg DOL uonoes DOL uonoes DOL uonoes 50 50 TROUBLESHOOTING 4 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely
37. CV Constant Voltage GMAW MIG Gas Metal Arc welding GMAW P MIG Gas Metal Arc welding Pulse GMAW PP MIG Gas Metal Arc welding Pulse on Pulse GTAW TIG Gas Tungsten Arc welding SMAW STICK Shielded Metal Arc welding FCAW INNERSHIELD Flux Core Arc Welding POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC gt 818 EIS 2 1 Return to Section Return to Master TOC PRODUCT DESCRIPTION The POWER MIG 300 is a complete semiautomatic multi process DC arc welding machine offering CV and CC DC welding It is rated for 300 amps 32 volts at a 60 duty cycle The standard machine is equipped to weld CC Stick CC GTAW CV FCAW and synergic and non synergic CV GMAW GMAW P and Pulse on Pulse and Power Mode welding processes See the descriptions for Pulse on Pulse and Power Mode welding processes later in this section 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 All of the other mode numbers designated as CV are synergic Again WFS is shown on the left meter and volt
38. Make certain that the input power switch is in the ON position Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel Blown or missing fuses in the input line Check for thermal light on case 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 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 Check for the correct input volt age atthe line switch L1 L2 See Wiring Diagram Check for loose or faulty con nections between the line switch and the reconnect panel Perform the Main Transformer Check the red LED s 1 amp 2 on the digital power supply board They should be lit indicating that DC voltage is being applied to plugs J 42 and 43 See Wiring Diagram If LED s 1 amp 2 are not lit check for the presence of 42 VDC at plug J 41 pin 2 and pin 1 the 42 VDC is present and LED s 1 amp 2 are not lit the digital power supply board may be faulty If the 42 VDC is not present at plug 41 perform the Rectifier Test CAUTION If any reason you do not understand the test procedures are unable to perform the test repairs safely
39. Return to Section TOC ILLUMINATED LE 1043 44 INDICATES VOLTAGES gt BE BEING SUPPLIED TO J42 LOCATED ON LOCATED ON SECONDARY CHOPPER BOARD ILLUMINATED LE INDICATES VOLTAGES ARE WINDINGS HEATSINK BEING SUPPLIED TO J43 5232 SUPPLY SPI DISPLAY VOLTAGE FEEDBACK 943 TAN COMMUNICATION FOR WELDFILE zs vi aL SUPPLY DOWNLOADS 31048 n LOCATED ONTOP LOCATED AT BOTTOM OF BOARD P C BOARD COMPARTMENT CONPARTMENT ILLUMINATES WHEN ILLUMINATES WHEN ILLUMINATES WHEN ILLUMINATES WHEN LOCATED ON DIVIDER PLACED AT A 45 ANGLE DISPLAYING WFS DISPLAYING 5 DISPLAYING VOLTS DISPLAYING TRIM PANEL INTHE WIRE DRIVE CONTROL COMPARTMENT TOROID 254 BOARD o9 SCHEMATIC G3789 24 DUAL ENCODER PRESENT 7PIN FEEDHEAD ONTR SPOOL GUNPUSH PULL P C BOARD TT ON CODE 10562 ONLY FOR MECHANICAL ENCODERS LOCATED BEHIND THE CTO SCHEMATIC 63883 2245578 THE MACHINE BENE REFER TOIS ON FERRED INSULATING WIRE DRIVE CONTROLS THE WIRE PWM PULSE WIDTH VOLTAGE BETWEEN P C BOARD THE DISPLAY BOARD PANEL REMOVE THE PWMCONTROLLED DRIVE FUNCTIONS AND 5 BAN aS RES CONNECTS DIRECTLY TO THE WIRE DRIVE ASSEMBLY GS VDE WEN GES LOCATED ON THE GAS SOLENOID ooo DEPENDING ON TOGAIN ACCESS FLOWING COIL CASE BACK 408 CURRENT THROUGH OPTION PANEL MEASURES 21 OHMS LEMSODA 4 SPOOL GUN 12VDC COIL P C BOARD SCHEMATIC G3997 1 CONT
40. The gun liner may be clogged Check or replace Perform the Wire Drive Motor and Tachometer Feedback The Wire Speed Control Encoder may be faulty If code is 10562 below change Encoder PCB If code is above 10562 Perform Encoder Test The Feeder Head Board may be faulty Replace The machine stops feeding wire while welding Check for adequate wire supply Check for mechanical restric tions in the wire feeding path The gun may be clogged Make sure the gun liner and tip are correct for wire size being used Check spindle for ease of rota tion Check to see if the spot timer has been activated Check the motor armature cur rent Normal armature current is 2 0 to 2 7 amps maximum If the motor armature currentis normal the Feeder Board may be faulty Replace If the motor armature current is 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 CAUTION If 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 POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E 2 st olg iz 8 e 5 5 ply o
41. gt 833 R99 um 148 cV FILENAME 63789 10 1 FRAME CONNECTION o 10 0K 10 0K e THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC h pope AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF LINCOLN ELECTRIC CO GROUND CONNECTION Rex Ki 507 UNLESS OTHERWISE SPECIFIED TOLERAwce Ch ge Sht No x INFO 1 a NOTES 5 OTHERWISE SPECIFIED THE LINCOLN ELECTRIC CO NVERTER WELDERS 3 R3 THERMOSTA SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE cies oe 8 4 2000P CLEVELAND OHIO U S A SUBJECT SCHEMATIC DIGITAL CONTROL 5 5 SINGLE THREE PHASE DETECT 175 WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES IS 5 OF DEGREE po O1 SCALE NONE Sir E t t t HON EGET COMPONENTS UR CIRCUIT OP CONTROLS A CONMON CODE MATERIAL C47 TO AREE pate 08 02 2000 SUP S D G No C3789 1D0 5 E A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 59 ELECTRIC POWER MIG 300 oe ELECTRICAL DIAGRAMS SCHEMATIC DIGITAL CONTROL BOARD 2 CODE 10562 11098
42. lt 13 lt js HE UN 716 16 FEEDER BOARD a 2 8 8 802 2 6 f 1 1 4 804 lt 4 lt 806 6 SPOOL GUN PUSH PULL SWITCH LEAD COLOR CODE B BLACK OR GRAY FLEX R RED OR PINK W WHITE G GREEN W YELLOW STRIPE 4 ic 3 o ojo OJO oe 512 2 5 5 10 5 5 8 puc 7 1 00000 o lo im 16 6 7 CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROMCONPONENT SIDE OF BOARD SPI SPOOL GUN BOARD L2 THRU L9 ARE RF CHOKES 4444 ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR yee uy YYYY D gt 2 olo J32 2323 mf J82 181 gt lt 7 lt PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE VIEWED FROM LEAD SIDE OF RECEPTACLE 9 PIN 9 150 50 lt 12 2 2001 Return to Section Return to Master TOC 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 3 POWER MIG 300 adi ELECTRICAL DIAGRAMS
43. 16 332k o 9 EN HBITI 40 o151 1 0182 OIW EN SHIFTI 41 pog 1 0282 iL RU TRIGGER INTERFACE 55 1 INPUT OK 21 9 34 Vota A 20 0K lt 6 INVSS 2 10 DG201ADY 475K 5 5 15 1 1 0681 1 0782 D 01 R39 IW CS3 3 1 0882 3 1 D ec us mm INV S2_5 Dv Gs o jc o 1032 gt POT SENSE 01 201 2501 2501 2501 2501 243 t INV CS1 6 LOCK 1 50V 50V 50V 50V ME 50V tr T 500 L 1 01081 1 01082 2 zeok a oso rook INV MOSI 7 91351 4701182 Sj IW 2 joiw CONNECTED nS 150 8 1701281 1 01282 27 EN ENCOMEETED 2C gs RET f y TRIGGER SW 12 1 01382 23 05 x12 22 15sPl 6571 V 243 d 332 40V 231001481 1 01482 SHT 2 M_OVL Ld p th o1se1 1 01582 21 lt POT SENSE ilm Bm il 9936 170168220 0 a sov W ADCS 18 1701781 1 01782 L9 AD MISO IN SQK Hio Te dt AD MOSI roi 1 a 24 100 5 rosea 2 351 0 6TS1 TMS 4l 1 0 6152 2311 0 0S8 Lu i 5 R _ Vise H Amo zar 9 OW AV ss V R29 us 243 A D CONVERTER iw 22252 75 oF o 2 0MHZ OSCILLATOR 08 GN PoF x p F 05 37 O CY22921 AD MOSI 1 pin id 400V s ma PWM_CLK 1 76 00T gt 4 ano SHTOWN OE CLKC FNC 5VREF al REMOTE S2 SUSPND CLK
44. ENCODER BOARD Below code 10900 GUN TRIGGER AND THUMB SWITCH SPOOL GUN PUSH PULL SWITCH 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 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC ojo e iz g 2 5 Return to Section Return to Master TOC Return to Master TOC E 8 E 8 THEORY OF OPERATION THERMAL 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 op
45. POWER MIG 300 LINCOLN F 35 F 35 TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED MACHINE LOADED TO 250 AMPS AT 26 VDC Return to Section TOC Return to Master TOC o 2 5 2 3 Return to Master TOC 20 0 V 2 0 MS DIV 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 5 time FE Sis NOTE Scope probes connected at the machine output terminals probe to electrode probe to work PEN gt 9 2 8 5 SCOPE SETTINGS E Volts Div 20V Div Horizontal S weep 5 ms Div DC Trigger e Internal Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 36 36 TROUBLESHOOTING amp REPAIR MOTOR amp GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT WARNING Return to Section TOC Return to Master TOC 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 s
46. Return to Master TOC POWER MIG 300 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio e 515 lt gt elg lt 515 2 21 cc a Return to Section TOC Return to Master TOC B 2 Read entire Operation section before operating the POWER MIG 300 WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground e Always wear dry gloves insulating FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone 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 li NM 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 OPERATION B 2 COMMON WELDING ABBREVIA TIONS WFS Wire Feed Speed CC Constant Current
47. 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
48. 09 1 DIODES 1A 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET Vi Vi POWER SUPPLY SOURCE POINT 57 CONNECTION 77 7 FRAME CONNECTION o THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC CO 1 EARTH GROUND CONNECTION ND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO 7 EQUIP o z SINCE COMPONENTS OR CIRCUITRY ON PRINTED Ch ge Sht No THE LINCOLN ELECTRIC COMMON CONTROLS CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING CLEVELAND OHIO U S A sussecr SCHEMATIC SPI SPOOL GUN PCB 9 THIS DIAGRAM NOT SHOW THE EXACT pos 01 scale NONE COMPONENTS OR CIRCUITRY OF CONTROLS HAVING t 01 16 2007 m SHT 3997 1 0 1 COMMON CODE NUMBE OR DATE CHK SuP s o c NO 51 3 9 NOTE This diagram is for reference only It may not be accurate for machines covered by this manual LINCOLN 59 ELECTRIC POWER MIG 300 oe ELECTRICAL DIAGRAMS udis SCHEMATIC SPOOL GUN PC BOARD CODE 10562 11098 SHEET 2
49. G 6 ENTIRE MACHINE SCHEMATIC CODE 11097 and 11098 64512 G 7 CONTROL PC BOARD SCHEMATIC 1 CODE 10562 11098 G3789 1D0 1 G 8 CONTROL PC BOARD SCHEMATIC 2 CODE 10562 11098 63789 100 2 G 9 CONTROL PC BOARD SCHEMATIC 3 CODE 10562 11098 G3789 1D0 3 G 10 CONTROL PC BOARD SCHEMATIC 4 CODE 10562 11098 63789 100 4 6 11 CONTROL PC BOARD ASSEMBLY CODE 10562 11098 111088 1 ii POWER SUPPLY PC BOARD SCHEMATIC CODE 10562 11098 63631 G 12 9 POWER SUPPLY PC BOARD ASSEMBLY CODE 10562 11098 63632 2 ii E CHOPPER PC BOARD SCHEMATIC CODE 10562 11098 20046 112 G 13 m CHOPPER PC BOARD ASSEMBLY CODE 10562 11098 111497 1 ii 9 MSP3 PC BOARD SCHEMATIC CODE 10562 11098 111612 G 14 BOARD ASSEMBLY CODE 10562 11098 19790 1 6 15 FEEDER PC BOARD SCHEMATIC CODE 10562 11098 3883 SHEET 1 6 16 5 FEEDER PC BOARD SCHEMATIC CODE 10562 11098 3883 SHEET 2 6 17 9 FEEDER PC BOARD ASSEMBLY CODE 10562 11098 63884 SPOOL GUN PC BOARD SCHEMATIC CODE 10562 11098 63997 SHEET 1 G 18 SPOOL GUN PC BOARD SCHEMATIC CODE 10562 11098 63997 SHEET 2 G 19 SPOOL GUN PC BOARD ASSEMBLY CODE 10562 11098 20159
50. MAIN TRANSFORMER AND CHOKE ASSEMBLY REMOVAL 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 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 assembly can now be lifted enough to allow the main transformer and choke assembly to be removed 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 REPLACEMENT PROCEDURE For lead reassembly steps also see the Wiring Diagram 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 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 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 6 Connect leads H2 H3 and H5 to the reconnect panel 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
51. Make sure shielding gas is cor rect and flow is proper Make sure the weld joint is not contaminated l Check the Output Voltage 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 3 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 POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E 2 E olg iz 212 515 Return to Section Return to Master TOC F 10 F 10 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS he contact tip seizes in the gas dif fuser POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS 1 The tip being over heated due to excessive current and or high duty cycle welding A light application of high temper ature anti seize lubricant such as Lincoln E2607 Graphite Grease may be applied to the contact tip threads TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check the Output V
52. POWER MIG 300 LINCOLN 5 F 45 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E a 23 e 5 5 ply ajo Return to Section TOC Return to Master TOC F 46 F 46 TROUBLESHOOTING amp 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 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
53. REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT continued 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 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 10 Disconnect leads X5 and X6 from the control recti fier spade connectors 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 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 atthe bottom right and H4 is at the bottom left Note that leads H1 and which go to the reconnect panel attach at these same terminals 14 Using a 1 2 in wrench and socket wrench discon nect heavy lead B2 from the choke 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
54. SOLID EDGE Return to Master TOC 170 Return to Section NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER MIG 300 os ELECTRICAL DIAGRAMS me SCHEMATIC DIGITAL CONTROL PC BOARD 1 CODE 10562 11098
55. 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 Return to Section TOC Return to Master TOC 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 O10 a gt 23 e 5 5 ply ajo Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC OJO Fle 2 PEN Sm 5 2 Return to Section Return to Master TOC F 22 F 22 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER ASSEMBLY TEST continued FIGURE 7 OUTPUT RECTIFIER ASSEMBLY LOCATION TEST PROCEDURE 1 Disconnect the main AC input power to the machine 2 Perform the Chopper Assembly Capacitor Discharge procedure 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
56. UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET C POWER SUPPLY SOURCE POINT ono COMMON CONNECTION 77 FRAME CONNECTION EARTH GROUND CONNECTION 3 9 Vcc Vdd O O DDIDDIE THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC MAY NOT BE DUPLICATED COMMUNICATED ROPRIETARY amp CONFIDENTIAL _ 13 _ 5 C E TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC 2 2 1 91 aol SINCE COMPONENTS OR CIRCUITRY ON A 2 50V m 2110 50V PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION REFERENCE EQUIPMENT YPE CHOPPERS PAGE 01 OF 1 55 WITHOUT AFFECTING THE INTERCHANGE DRAWN BY ic _ 2 2 13 DOCUMENT DOCUMENT ABILITY OF COMPLETE BOARD THIS SUBJECT SCHEMATIC 300 A CHOPPER PCR 918 DIAGRAM MAY NOT SHOW THE EXACT LC 2 NUMBER REVISION COMPONENTS OR CIRCUITRY OF CONTROLS MATERIAL APPROVAL PROJECT 515 V HAVING COMMON CODE NUMBER APPROVED DRAWING pisposition NA DATE 03 19 2003 CRM35004 20046 112 NOTE This diagram is for reference only It may not accurate for machines covered by this manual 3 POWER MIG 300 ae ELECTRICAL DIAGRAMS SCHEMATIC MSP3 PC BOARD CODE 10562 11098
57. WIRING DIAGRAM POWER MIG 300 CODE 10952 ONLY S3RS232 CONNECTOR 303 4h DIGITAL POWER SUPPLY BOARD UC CONTROL RECTIFIER Return to Section TOC Return to Master TOC SHIELDED CABLE Return to Section Return to Master TOC DISPLAY BOARD GUN TRIGGER PANEL ENCODERS 1234 VOLTS TRIM 5 5 SPOOL Or 09 9 PUSHPULL Gv 75A SPOOL GUN SHIELDED CABLE ANPHENOL QO 8 PUSH PULL SWITCH GAS SOLENOID 8511 858 857 8510 ojo O10 E Els a 23 5 5 ply so 0 LEAD COLOR CODE TPITAPTTTPTATTTTTTTTATTTT B BLACK OR GRAY R RED OR PINK W WHITE G GREEN WYELLOW STRIPE 5 GREEN DWEL OWSTRP L E 3 FEEDER BOARD ojo CONNECTOR CAVITY NUMBERING SEQUENCE VIEWED FROMCOMPONENT SIDE OF BOARD L2 THRU LO ARE RF CHOKES ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE LULELET P re 11 VIEWED FROM LEAD SIDE OF RECEPTACLE SHIELDED CABLE G4068 Return to Section TOC Return to Master TOC 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 E POWER MIG 300 di ELECTRICAL DIAGRAMS WIRING DIAGRAM POWER MIG 300 CODE 10958 AND 11000 ONLY 5385232
58. ajo Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE E 2 INPUT VOLTAGE AND MAIN TRANSFORMER MAIN OUTPUT CHOPPER POS TRANSFORMER RECTIFIER ASSEMBLY OUTPUT ouTPUT SUN CHOKE TERMINAL CURRENT TRANSDUCER rc quee RECONNECT NEG OUTPUT CURRENT TERMINAL LINE POWER 20 VDC FEEDBACK SWITCH BOARD PWM FEEDBACK DIODE CONTROL SIGNALS RECTIFIER 15 15 5 VDC RELAY a UL FAN WELD CONTROL BOARD CONNECTOR MOTOR TE 40 FROM WELD VDC TO FAN RELAY CONTROL BOARD THERMOSTATS ARCLINK SHIELDED CABLE AND SPI COMMUNICATIONS FOOT AMPTROL OR REMOTE 6 PIN AMPHENOL 45 VDC 40 VDC C SPOOL FEEDER ENCODER DISPLAY 24 VDC GUN CABLE BOARD BOARD BOARD BOARD Below code 10900 GUN TRIGGER AND THUMB SWITCH SPOOL GUN OR PUSH PULL GUN 7 PIN AMPHENOL 1 SPOOL GUN GAS PUSH PULL C SOLENOID SWITCH Mechanical Encoders Above code 10900 WIRE DRIVE MOTOR GENERAL DESCRIPTION The Power MIG 300 is a complete semiautomatic digital microcomputer based control system allows multi process DC arc welding machine offering CV and and accurate adjustment of weld parameters CC DC welding It is rated for 300 amps 32 volts at through the multi process panel located on the front of 60 duty cycle The standard machine is equipped to the machine The Power MIG 300 is equipped with a weld CC Stick CC GTAW CV FCAW and syner
59. 035 0 9mm and 045 1 2mm are included for WARNING the welder power switch off before installing gun and cable LINER INSTALLATION AND TRIMMING INSTRUCTION SEE FIGURE A 3 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 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 Seat Liner bushing into back of gun Secure Liner by tightening set screw Do not install the gas dif fuser at this time 6 Lay the cable straight and trim Liner to 9 16 Remove burrs 7 Secure the gas diffuser into the tube 8 Tighten the set screw against the Liner CAUTION This screw should only be gently tightened Over tightening will split or collapse the liner and cause poor wire feeding INSTALLATION A 5 GUN amp CABLE ASSEMBLY INSTALLED INTO THE POWER MIG 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 3 Connect the gun trigger connector from the gun and cable to the mating receptacle inside
60. 1 ENCODER PC BOARD SCHEMATIC CODE 10562 ONLY 111558 G 20 ENCODER PC BOARD ASSEMBLY CODE 10562 ONLY 11559 2 G 21 DISPLAY PC BOARD SCHEMATIC CODE 10562 11098 111108 G 22 DISPLAY PC BOARD ASSEMBLY CODE 10562 11098 111757 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 Q 2 Return to Master POWER MIG 300 LINCOLN 5 ae ELECTRICAL DIAGRAMS me WIRING DIAGRAM POWER MIG 300 CODE 10562 ONLY S3RS232 CONNECTOR DISPLAY ENCODER MSP Ill CONTROL f 1 DIGITAL POWER SUPPLY BOARD 1 gt BOARD BOARD BOARD BOARD gt 2 gt 253 3 3 24 H2 id FLEX CIRCUIT SHIELDED 1 257 Y 25 m soin a CABLE 12 lt yY 251 MEM 3 408 403 1104 437 405 401 2 bs ee 406 402 1103 8 HIELDED e Y CABLE 6 lt Ke Return to Section TOC Return to Master TOC lt 10 ED SPOOL GUN BOARD FEEDER BOARD K CABLE P C BOARD CONNECTION DETAIL
61. 12 TROUBLESHOOTING amp 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 J umper leads Wiring Diagram POWER MIG 300 LINCOLN 5 F 12 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo O10 E e a 2 2 5 5 o Return to Section Return to Master TOC F 13 F 13 TROUBLESHOOTING amp REPAIR CHOPPER BOARD CAPACITOR DISCHARGE PROCEDURE continued FIGURE F 1 CHOPPER BOARD CAPACITOR TERMI
62. 16 Control Rectflek d exe PRI RE F 19 Output Rectifier Assembly Test F 21 Wire Drive Motor and Tachometer Feedback Test F 23 Encoder PC Board Test 10562 amp 1 0 101212 nnns F 26 2 Current Transducer TeSE aon ct ER C OR F 29 Power Mig Scrolling Dashes F 32 5 Oscilloscope WavwvefOorms RR ERR 34 Removal and Replacement 36 Motor amp Gear Box Removal and 0 0 36 Output Rectifier Removal and 1 F 40 Chopper Board Assembly Removal and F 43 9 Main Transformer and Output Choke Removal and F 46 2 Fan Motor Assembly Removal 50 Voltage amp Current Calibration F 52 g R test after R ebria
63. 5028 os SWI 1959 A A 459 MTO T 5 MTZI SIS Pore eR le 7 2X 68 aes ISOW 38855555555 D OAA A gt 5728101 oz 8910 1 18910 115 3 4300N3 8510 1 i a 27 28710 1 9 56 Te TO 1 gr 29 10 1 Isa iz no 1X IgZI0 1 3 1 1O 82 lt 27 8010 1 43G03N3 T 2960 1 1960 1 ty d 5 8 T _ 7212901 1990 15 W3dWnr LNOHLIM 9 SOA O 123138 dIH3 0 08 MEO iE 1 1 82 YOST 2920 1 7920 1 2 oer 518 7H 1810 15 x MIO MIO MIO MTO M xi xeu 2 169 10 a p 1955 IdSS LI e N 6 901 491590 0 901 491590 0 uunjeH 901 J91Se N 0 901 J91Se N 01 DOL uonoes uumeg DOL uonoes DOL uonoes DOL uonoes Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o 5 5 PEN 9 gt 212 5 5 Return to Section Return to Master TOC 6221 ELECTRICAL DIAGRAMS e PC BOARD ASSEMBLY ENCODER PC BOARD CODE 10562 ONLY N B ITEM R PART No DESCRIPTION N B L11166 1 FLEX CIRCUIT ELECTRICAL INS
64. 6 52 v 1 L H 7 GSPI GSPI Tus lax 5135 25 NOTE This diagram is for reference only It may not be accurate for machines covered by this manual POWER MIG 300 6 15 ELECTRICAL DIAGRAMS G15 PC BOARD ASSEMBLY MSP3 PANEL CODE 10562 11098 Return to Section TOC Return to Master TOC ITEM REQ D PART No DESCRIPTION 8__ 151762 LED SPACER __ 111661 FLEX CIRCUIT ________ 0102 3539 ELECTRICAL INSULATING COMPOUND FOR ITEMS BELOWREFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATIONS GROUNDSIDE C1 C2 C3 C4 C5 06 C7 C8 C10 15 516668 11 0 1 50V 10 C11 C12 C13 C14 C15 C16 34 i 182810 CONNECTOR MOLEXMINLPCB T PIN I 958 GORNECTOR MALE PTL BP LED1 LED2 LED3 LED4 LED5 T13657 6 LED T 1 RED HLMP LED6 LED7 LED8 R1 R2 R12 R13 R14 R15 R16 519400 1001 RESISTOR 1 4W 1 00K 1 R17 R18 R19 R20 R21 R22 R23 R24 R25 Ra FS RO RT AGRO 6 5184001212 RESISTOR MF 121K 1 Return to Section TOC Return to Master TOC ojo o E 2 a 23 mlt 5 5 ply ajo LEDS LEDS Pee Cee LEDE re 0000000580 UNLESS OTHERMSE SPECIFIED CAPACITANCE MFD VOLTS A INDUCTANCE HENRIES RESISTANCE 5 M19790 2 Return to Section TOC Return to Master TOC NOTE Linc
65. A 5 DIGITAL CONTROL cle vi NA SINCE COMPONENTS OR CIRCUITRY ON PRINTED CIRCUIT BOARD MAY CHANGE ON 3 PLACE DECIMALS IS 002 8 1 2000P 03 NONE Tus V Wc WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES 15 5 OF A DEGREE PG SCALE SHT 5 5 15 SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE MATERIAL TOLERANCE TO AGREE DR FM pate 08 02 2000 chk Saot 897 63789 100 Siz 5 NUMBER WITH PUBLISHED STANDARDS 73 cc NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 5 ELECTRIC POWER MIG 300 een ELECTRICAL DIAGRAMS SM SCHEMATIC DIGITAL CONTROL PC BOARD 4 CODE 10562 11098
66. COMPLETE BOARD THE SUBJECT SCHEMATIC 42VAC amp ARCLINK FOR PCB poe SCALE THIS COMPONENTS OR CIRCUITRY OF CONTROLS MATERIAL APPROVAL PROJECT E HAVING COMMON CODE NUMBER APPROVED DRAWING DATE 05 12 2003 CRM35415 G 3883 1E0 A NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Master TOC LINCOLN 3 POWER MIG 300 G 17 ELECTRICAL DIAGRAMS 6 17 SCHEMATIC FEEDER PC BOARD BOARD CODE 10562 11098 SHEET 2
67. 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 Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items
68. 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 5 Seat Liner bushing into back of gun Secure Liner by tightening set screw Do not install the gas dif fuser at this time 6 Lay the cable straight and trim Liner to 9 16 Remove burrs 7 Secure the gas diffuser into the tube 8 Tighten the set screw against the Liner CAUTION This screw should only be gently tightened Over tightening will split or collapse the liner and cause poor wire feeding FIGURE D 1 FEEDR END CABLE HANDLE INSULATION TUBE CONNECTOR BRASS CABLE 7 MOLDED GAS PLUG SET SCREW TIGHT AGIANST BRASS CABLE CONNECTOR CLAMPING SCREW LINER ASSEMBLY LINER BUSHING TO BE SEATED GUN HANDLE GUN TUBE ZA 9 16 14 3mm SET SCREW 38 LINER TRIM LENGTH GAS NOZZLE INSULATION GAS NOZZLE POWER MIG 300 LINCOLN 5 Section 1 Section 1 TABLE OF CONTENTS e THEORY OF OPERATION SECTION Bilans ru e RE Section E g E General DESCrIPUON RR E 2 2 Input Voltage and Main Transformer enne ene E 3 Input Rectifier Chopper Assembly And Feedback 4 Diode Control Rectifier and Power Board eene E 5 Weld Control Board 4 ett E
69. MISADJ USTMENT 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 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 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 and Diagrams S ection Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures 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 POWER MIG 300 LINCOLN 5 Return to Section TOC Retur
70. 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 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 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 If the LED next to a weld parameter 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 6 ON OFF POWER SWITCH POWER MIG 300 LINCOLN 5 OPERATION Bu 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 approximatel
71. POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo o E a gt 3 5 5 o ajo Return to Section TOC Return to Master TOC E 4 E 4 THEORY OF OPERATION FIGURE E 4 DIODE CONTROL RECTIFIER AND POWER BOARD MAIN TRANSFORMER RECONNECT PANEL LINE 115 SWITCH les e RELAY FAN MOTOR 40 FROMWELD VDC CONTROL BOARD FOOT AMPTROL OR 15 6 AMPHENOL prie SHIELDED m PERDER BOARD SPOOL GUN PUSH PULL SWITCH SPOOL GUN OR PUSH PULL GUN 7 PIN AMPHENOL C PANE OUTPUT RECTIFIER HNDE POWER 20 VDC BOARD DIODE CONTROL PWM RECTIFIER 41 15 45 IGBT C THERMOSTATS CHOPPER POS ASSEMBLY OUTPUT CHOKE TERMINAL GUN 9 o L Fra CURRENT TRANSDUCER OUTPUT CURRENT TERMINAL FEEDBACK VOLTAGE FEEDBACK SIGNALS DRIVE WELD CONTROL BOARD 9232 TO FAN RELAY SHIELDED CABLE AND SPI COMMUNICATIONS MSP DISPLAY BOARD BOARD ARCLINK 5 VDC ENCODER BOARD Below code 10900 GUN TRIGGER AND THUMB SWITCH Mechanical Encoders Above code 10900 INPUT RECTIFIER ASSEMBLY AND FEEDBACK CHOPPER The 60 VAC output from the main transformer sec ondary is connected to an input rectifier The resultant 80 VDC is appl
72. accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations POWER MIG 300 LINCOLN 5 Return to Master Return to Master TOC Q 5 Return to Master SAFETY i PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte le
73. 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 CONTROL SYNONYM SETTING APPLICATION AND RESULT GMAW S Short circuiting metal transfer GMAW P Pulsed spray metal transfer Pulse on Pulse Aluminum Only Arc Force Inductance or Pinch Control Pulsed frequency control Pulsed frequency array control Lower 1 to 10 for low types of electrodes Higher 1 to 10 for cellulosic and other types Setting 1 to 10 for softer higher energy arc Setting 1 to 10 for a crisper lower energy arc Minus settings reduces frequency Plus settings increase frequency Minus settings result in lower array frequency and the plus settings increase the array frequency POWER MIG 300 LINCOLN 5 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 puddle and larger droplet size The lower settings reduce the droplet size and reduce energy to the arc Wider arc cone and weld bead Narrower arc cone and narrower weld bead Minus settings result in a wider bead with more distinct ripples Plus settings narrow the resultant bead and the
74. 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 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 10096 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 Carbon steel electrodes employed in GMAW S usually p
75. be displayed and can be changed by toggling the SET switch up or down The default value is OFF 0 seconds Spot can be adjusted from 0 to 10 0 seconds in 0 1 sec ond increments 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 POWER MIG 300 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 o 2 5 Return to Section TOC Return to Master TOC Q 5 PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS 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 3 Remove the outside wire guide retaining plate by loosening the two large knurled screws 4 Twist the drive roll retaining mechanism to the unlocked position as shown below and remove the drive roll See Figure B 3 FIGURE 5 Remove the insid
76. connections If the lead connection check OK then change the encoder POWER MIG 300 LINCOLN 5 29 29 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER TEST WARNING Return to Section TOC Return to Master TOC 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 olo 915 912 519 DESCRIPTION olo This test will determine if the current transducer and associated wiring are functioning cor rectly 3 3 Pc MATERIALS NEEDED Volt Ohmmeter 3 8 Nut driver olo E e olg iz 8 e 5 5 ply Return to Section Return to Master TOC POWER MIG 300 LINCOLN 30 30 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER TEST continued FIGURE F 10 Return to Section TOC Return to Master TOC nooo Doo oo 20000000
77. 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 FIGURE B 6 N PULSES PULSES HIGH HEAT LOW HEAT PULSES 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 FIGURE B 7 OPERATION B 12 When Arc Control is used in the Pulse on Pulse modes it does the same things it does in the other pulsed mod
78. in mode 200 apply a resis tive to the welding output terminals approx 106 ohms set the machine output to 250 4 amps and enable the weld terminals by pressing the trigger switch 5 6 Using the test meters note the output voltage and current 6 7 The Power Mig 300 voltmeter must match the test meter reading to within 1 volt 7 8 The Power Mig 300 ammeter must match the test meter within 5 amps 8 9 If the volt meter does not meet the specifica tion then proceed to the Voltage Calibration 10 If the ammeter does not meet the specifica tion then proceed to the Current Calibration or current setting of the Power Mig be sure to read the entire voltage or current 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 VOLTAGE CALIBRATION Connectthe resistive load bank approximate ly 106 ohms or 250 amps and test voltmeter to the welding output terminals Toggle and hold in the mode select switch in the up position Tum on the Power Mig 300 Rotate the right hand output control knob until the display reads vol Release the mode select switch The left display will change to VcAL to indi cate that voltage
79. in the up position Turn on the Power Mig 300 Once the display reads Pres Spin release the mode select switch Rotate the output knob until the display reads cur 5 1 1 I 1 1 14 gt 15 Toggle the Mode Select switch once The left display will change to ICAL to indi cate that current calibration is in progress The right hand display will scroll the following message Adj rEnc SorEAL cur 250A Adjust the right hand output control knob until the actual output current reading on the test ammeter is 250 amps 2A Wait for the machine s output to be automati cally turned off and then back on Adjustthe output control knob again if neces sary to make the actual output current read ing on the test ammeter 250 amps 2A Wait for the machine s output to be automati cally turned off and then back on Repeat above two steps if necessary Toggle the mode select switch up and release the switch to save the calibration setting The right display will display the message SAVEd Within 5 seconds hold the mode set switch in the up position until the right display stops blinking The machine will reset to normal operation after a few seconds 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
80. is not binding Verify wire spool is not binding Check current at drive motor exceeds 3 50amps for 10 0 seconds change drive motor Feed Head Board can t be found Turn the machine off and back on to reset the machine If condition per sists contact and autho rized Lincoln Field Service Facility Using machine schematic Check LED 8 on Control Bd If not on check for 5VDC atleads 1103 amp 1104 If LED 8 is on check for 42VDC at Feed Head Bd If there Feed Head Bd may be faulty 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 1 800 833 9353 Display Board can t be found Scrolling dashes Turn the machine off and back on to reset the machine Perform Clear all test CAUTION If 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 POWER MIG 300 LINCOLN 5 Check for bad connec tions at Display Board The Display Board may be faulty Replace Perform Clear all test Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E a 23 e 5 5 ply ajo Return to Section TOC Return to Master TOC F
81. output is enabled the meter will display ON When there 15 no output the meter will display OFF 3 OUTPUT CONTROLS The POWER MIG 300 has 2 encoder knobs to adjust weld parameters Each encoder changes the displayed value of the meter located directly above that encoder 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 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 B 4 OPERATIONS E 5 MULTI PROCESS PANEL This panel enables selection of weld modes as well as adjustment of certain weld parameters within each weld mode The eight discrete LED s are used to identify which selec tion will be shown on the display The possible selections are Weld Mode Process selection choices Preflow Postflow Run In Choice of weld parameters Start that can be adjusted Arc Control Complete descriptions of e Crater each parameter are found Burnback later in this section Spot Only one LED will be illuminated at any time The Weld
82. 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 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 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 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 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 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 B 8 OPER
83. the equipment being used 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 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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
84. 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 The following procedure settings for Aluminum 4043 can be used as initial settings for making test welds to determine final settings Wire Dia WFS Setting Arc Voltage In mm Spool Gun Setting 030 8 mm 035 9 mm 3 64 1 2 mm 4 Synergic Weld Modes 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 n 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 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 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 in
85. ul 109 70 E SHT RS WE FET_A earn SHT 4 15 10 Ds AS 43 ADDRISI 28 oF gt 1 105 size M ADDRIGI 10 4 ADS l x30 BYTE 104 s171 ATUS ADDRI7 p T 102 pfo angles ADDRIBI VHCLAD A SHT 23 lt SYS_RESET 101 969 ADDRI9I A 4 DA 03 1002 A10 BO ADDRILOI f 5 fto gt 9 9 ADDRILLI TA LOOV 400V Sir FPGA INT 98 oe 1257 ADDRILZI VHCLAD VHCLAD 29 6 8 SHT 2 INT CAN logs X24 13 56 ADDRI13 37 4 z SP FPGA BAD A1457 0084 INT 9 m SHT 4 INT 100 93 aspe ADRS ADRII sur 24 SHT 2 15V REY el 100V SHT 5 0 61 19 Aig 60 ADDRI16 ji 5 3 3 TPUIO 3 1763 ADDRI171 45V sc 9T eT LEVEL IN wel ots TPUCHL eke ADDRIL8 SHT 2 E 01 16 SIGNAL 32 A9 6 175 50 ele 70 712 A20 Z DSP RESET 5 gt SHT 4 g 767K 8 750 TPUCHL A21 8 VPP CTRL ADDRILTI 22 are Olo SHT 2 z 29 5 A225 TACK SHT 4 Has wel TPUCHE CAN CS sz ADDRILSI D i n TPUCHT ADDRILAI al Vois 58 DATALLSI o A E 7 E 12 24 FPGA CS SHT 4 ADDRI13 Voi 81 o gt 082 4 er 23 9 FUNCEN SHT 4 008112 EN 1013B6 DATAI13 NORMAR lt 5 up 22 pucho 001139 DATAIOI ADDRILII 18 10 1 01285 12 9 5V FAULT n RBS 100 21 0111
86. 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 m For Codes 10952 amp Below See Figure F 11 15 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 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 Using a 7 16 in wrench remove panel covering the gear Using a Phillips head screwdriver remove gear 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 Grasp the motor gearbox assembly and wiggle it gently back and forth until it separates from the wire drive assembly Using a 3 8 nut driver remove 6 nuts that hold cover Remove panel to expose drive motor POWER MIG 300 LINCOLN 38 38 TROUBLESHOOTING 4 REPAIR MOTOR amp GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT continued REPLACEMENT PROCEDURE 1 Bolt the wire drive assembly to the wire drive 5 Attac
87. 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 POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Ke olg iz 212 515 oO Return to Section Return to Master TOC E 10 THEORY OF OPERATION FIGURE E 9 TYPICAL IGBT OUTPUTS 1 usec 48 usec 50 sec MINIMUM OUTPUT 24u sec 2 94 sec 50 gt MAXIMUM OUTPUT PULSE WIDTH MODULATION 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 MINIMUM OUTPUT 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 IGBT group conducting for 1 microsecond The nega tive portion is the other IGBT gro
88. 00 SVM160 B
89. 1 SPOOL GUN SHIELDED CABLE PUSH PULL 1 I SWITCH gt gt Od 0 O0 uU h UN 855A SPI SPOOL 8511 858 GUN BOARD J810 O o 5 5 o PEN 9 gt 8 e 5 5 1 8111 8115 LEAD COLOR CODE B BLACK OR GRAY R RED OR PINK W WHITE G GREEN W YELLOW STRIPE 1 8 1 6 14 CONNECTOR CAVITY NUMBER ING SEQUENCE VIEWED FROMCOMPONENT SIDE OF BOARD L2 THRU L9 ARE RF CHOKES ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR ato ole 0455 PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE VIEWED FROM LEAD SIDE OF RECEPTACLE TODD 656 9 4 9 G4511 Return to Section TOC Return to Master TOC 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 E POWER MIG 300 e ELECTRICAL DIAGRAMS G6 SCHEMATIC COMPLETE MACHINE CODE 10958 AND 11000 ONLY 91579 __ ENGINEERIN
90. 1 01782 1 017 1 8 BMISO R x25 z cea C65 HC132 1051 5 50 50 com gt STAT_LED_GRN STAT LED RED 045 MTR_SHTOWN_OUT E DIP SWITCH roe d 5 I 3 T DATAI151 DATAI14 DATAI131 121 TPUCHS S TPUCHE TPUCHLO TPUCHIA 12 TPUCHL3 1 amp SITPUCHLS MODCLK E amp TPUCHI Si TPUCHZ Te TPUCHB TITPUCHS A TPUCHA T 5 1 0 GCK3 36 1 0 6 51 33 1 0 658 1 10 5 24 100 11 1 0 6152 o GCK2 431 ooo 9 45V al gt O o 5 5 o PEN 9 gt
91. 232 35v LED2 B T 00 TP7 AM ES m 5 01 5 3 mus 50 ge 8 DE sov A a S N yx T av gt SHT 3 V ors232 4 15V E R132 4 6 6 200 06 046 5 62V 5V 9 5 12 MC145407DWw 0531 X 0601 0601 18V IS E 15 5 1w 059 XV MC1454070W i 66 tey A Mc JL 5 Viorsz32 lt lt gt SHT 134 685232 V M 052 150pF 18V 1000 1 2W 058 o O LOOK 18V L cas 1 2W O O 9 000 Vcrs232 5V GRS vue 10VRS232 gt V crs232 13 X16 8 Pc gt 66 MC1454070W 10 585232 gt 19 15 4L pae 10 55 1 VE 1 ces L MC145407DW 55 10 10 2 3 gt SHT 4 16V 18 CASAN a 16V GND Vss 7 16 u Jh 5 5 2 gt gt 012 C62 MC1454070W cu C92 EN 47 01 35v 50V i 5 ixis us gt 55 Lens gt 695232 V MC1454070W GREEN 2s D SEE Vans M M FULL DUPLEX RS232 COMMUNICATION LINK 695232 155 1 2 155 1 m 221k 5 5 043 a D 16V 5 vz 15V H LEDS gt 1 GREEN x ami 1 48 5 sv 8 475 EE 5 208 Ww 6 18 pe 5 ALE AS m2 JIN 1 EN LEDE E CONTROL BOARD OE VOLTAGE SUPP
92. 3 screws to gain access to the motor gearbox assembly 5 Disconnect motor leads 831 and 832 and tach leads 165 841 844 and 847at their in line connectors See the Wiring Diagram 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 Grasp the motor gearbox assembly and wiggle it gently back and forth until it separates from the wire drive assembly 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 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 Remove the wire drive assembly from the wire drive compartment 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 7 Rotate the adjustment arm assembly counterclock 11 wise to release the tension on the idle arm 8 Swing the idle arm up and away from the wire drive assembly 12 9 Remove the outer guide assembly from the wire drive assembly by loosening the thumb screws
93. 3 170163 1 0167 167 JACK SHT 1 DATAS 19010190 170200 220 DSP LK 3166 gig Vois 166 15 SHT 1 DATA 191 9 1 0199 199 XCS20 208 ADDRI12 193 1 0193 1 0198 198 DATA 15 i 2 194 20194 170197 197 DATAILAI DATANJI 195 0196 M XCS20 208 O O 0 131 AD DATAIO 131 Fie 0 9 SHT 1 1 03 1 045 e3 AD DATAIBI 518 aly SHT 1 1 04 1 044 fee AD DATACTI 9 6 EIE SHT 1 SPILLATCHT 51 05 yars pi AD DATAIGI gt OSP_DI6 1 08 1 042 2 _ 5 5 AD_DATAISI n 5 PSWISI 1 09 V 041 e AD DATALAI 105 1 046 1 095 Dee Miki m TIPWM T1CM 10PB3 19 AD DATAILO vos Ps PSWI amp I 17010 ES AEA AT 85 VREFHI TZPWM T2CM 10PB4 196 L d 05 B7 _ 2 48 1 053 P3 PSWITI Vo VT EP EE 53 T3PWM T3CM 1OPBS 197 SHT 3 SEL 1 0N 5117057 1 090 PO SPICS3 vois yag 1 036 B 54 XINT2 10 198 DA_CS 9 SPLSS 151 015 vne p 59 109 SHT 3 1 058 1 089 DSP DIO 17 XCS20 208 OSP_AIZ XINT3 IO TMRCLK IOPB7 5 SCK3 5 1 059 1 088 8 SPIMOSI 1 017 1 034 52 PONT SCITXD 10 44 DSP REN 19 B2 DSP A 3I 503 1087 BSCK a 1 019 1 032 ET 3 1 5 6d 1 062 voes EE SPICS1 EWE 201020 su
94. 38 0910 1449 voi B DATAILL pes 8 ak 221K 175 3 3 17 12 0212137 DATAI2 ADDRI 20 Ag 1001081 101 5 PTT MEETS p3 136 DATAI3I ADDRIBI 2 7 Vo Bo DATAISI E 5 ic 1 WE m 02 16V amp 15 p 133 2446 29 DATAIBI ale ov Ul teus 051132 DATAISI ADDRIGI 28 as 34 RE sm MISO 69 poso po 131 DATAI6 ADDRISI 28 yn vos t5 DATAI6I NK vo SHT 34 MOSI past 07 130 7 ADDRIAT 21 1 05 14 DATAISI 07 05 MISO7 SHT 34 Stk 612052 gap DATAIBI ADDRGI 4 DATAUI gt sHT 4 Sar enr AS THERMOSTAT or SHT 4 SPLCSO 682053 po 125 DATAISI ADDRIZI 43 12816 2071 1 93 00 DATADI 55007 41 028 100282138 Lab SHT SPLCSL 69 pass 010024 DATADOL ADORI 440 DATAIZI ina OVR CUR 42 onat Toe E RESET_RAMP ss SHT SPELES 70 2055 011 122 A 157 iy 018 FETB 2 vore B2 STROBE_AD sins SPLCS3 71 onse 012119 DATAI121 57 10017 DATAIOI CAPA OV 3 0881 1708B2 3l CAPB UV SHT 2 ETE 7 past 013 18 DATAII RAW Myr CAPA UV 5 gop 10982 30 0 SHT 2 5232 76 RxD 01 47 DATAM CST FETA 6 BLOCK 1 3 5116 DATAILSI 150 _ 39 NORMA 2 gt sur oror 1701082 29 SHT 3 7 c Ars 1
95. 6 Wire Drive Motor and Feedback siet oet Dea rr Rat Ea tcn E 7 Thermal Protection Over Current Protection and Wire Feeder 5 Protechom d X E 8 5 Insulated Gate Bipolar Transistor IGBT Operation E 9 8 Pulse Width edd 10 2 Chopper Technology 5 2 2 2 11 5 E FIGURE E 1 POWER MIG 300 BLOCK LOGIC DIAGRAM MAIN OUTPUT CHOPPER POS TRANSFORMER RECTIFIER ASSEMBLY OUTPUT OUTPUT CHOKE TERMINAL CURRENT TRANSDUCER DRIVE o O RECONNECT 5 ias OUTPUT E CURRENT TERMINAL LINE POWER FEEDBACK 5 5 T PK DIODE CONTROL RECTIFIER 15 15 5 VDC IGBT 3 FAN WELD CONTROL BOARD CONECTOR 40 FRoMweLD VDC CONTROL BOARD TO FAN RELAY SHIELDED CABLE AND SPI COMMUNICATIONS FOOT AMPTROL OR REMOTE 6 PIN AMPHENOL SPOOL GUN BOARD Below code 10900 SPOOL GUN OR PUSH PULL GUN 7 PIN AMPHENOL SPOOL GUN PUSH PULL SWITCH Mechanical Encoders Above code 10900 GAS SOLENOID WIRE DRIVE MOTOR Return to Master TOC POWER MIG 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo E 2 gt 23 e 5 5 ply
96. 6 c and 8 LINCOLN 5 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 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 FUMES AND GASES can be dangerous 40 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough 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 Do not weld in locations near chlorinated hydrocarbon vapo
97. 7 T 01 22 22 01 01 in E PA Tso MC68332GCPV25 25v T Sv Tso amp 1000 rar JIN 2 12 20 35 48 54 62 74 82 91 107120 128 13426 DATAIQ 15 e 19 101 els 175 elai 019 00 2 e RIS Jy gt 7 e gt E nA P 5 oO A RIG 755 TU 4102 E ou c 1 175 as m j 8 oH our 020 5103 Bru MISCL aa Qi TOOK 36V S BUTLGAN 40V M 5 05 gt Li VHCLAD Ve Ips 74HCST3PW gg he DATAIL1 1 24 50 8 06 06 13 2 12 DATAIBI aa pg 12 029 J6 07 i L B 45V Yi i c 2 m eL SHT 4 3 5 J4 n 220 7 REI R88 Hio 103 n 5V 175 Wo 2 nis SHT 4 THERMAL_LED 7 06 100K 5 DA 05A si 1 TTSK SEM Of 50V EM C25 031 080 076 lwp L L_14 B hom P MET vs ij W 2 INPUT output 7 465 V 45V 5 amp 100 ADDRILI EN 4 6 GNDI QUTPUT2 az 135 don z ADDRIZI 24 ny 000 2 gt __BATALO 4451BM 6402 TRO 10 01 27 gt 7 gt 5 ADDRISI 2 RIS HANE 775 sov exv sov 30v 35 02 001 zm ADDRI4 243 002 B3 DATA 21 2 lt elxlelxlalx ADDRISI 21 BS DATADI SN AL
98. ANSDUCER VAC C NEG POWER BOARD OUTPUT 15 15 5 Return to Section Return to Master TOC E RECONNECT PANEL CURRENT FEEDBACK 1 TERMINAL LINE SWITCH VOLTAGE FEEDBACK RS232 CONNECTOR DIODE CONTROL RECTIFIER PWM SIGNALS IGBT DRIVE WELD CONTROL BOARD MOTOR 40 FROM WELD FAN RELAY CONTROL BOARD THERMOSTATS ARCLINK SHIELDED CABLE Y SPI COMMUNICATIONS 45 VDC FOOT AMPTROL OR REMOTE 6 PIN AMPHENOL SPOOL SHIELDED MSP ENCODER DISPLAY 24 VDC GUN BOARD BOARD BOARD 7 Below code 10900 GUN TRIGGER AND THUMB SWITCH SPOOL GUN OR PUSH PULL GUN 7 PIN AMPHENOL SPOOL GUN GAS C PUSH PULL SOLENOID SWITCH Return to Section TOC Return to Master TOC Mechanical Encoders Above code 10900 WIRE DRIVE MOTOR WELD CONTROL BOARD 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
99. ATION B 8 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 the GMAW P weld modes Crater WFS and trim are adjustable This is indicated by the flashing LEDs next to WFS and TRIM Burnback 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 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 The default value is OFF 0 seconds Burnback time is adjustable from 0 to 0 25 seconds in 0 01 second increments Spot 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 Spot timer is selected by toggling the SELECT switch until the LED next to SPOT is lit The present SPOT time will
100. B SNC 3 ANZ 077 100 8 gt Bs 0 t ana ue re o 5 16 AD_MISO SVREF olg 1259 ma x E 02254 g XTAUN X8UF lg 5 SANS 155 gt XTALOUT 5 7 ane vrer L T ANB MC1450510W 50 ul c53 cns Zipr z V 12 AN10 GSPI 50 ADCS 1975 5 AD CLK 18 D GSPI 55 1 5VREF 155 1 HT 2 55 1 4 4 4 2L he 4 Ve T2137 1 6 155 1 C26 19 ea xB XB CLI C50 t46 5VREF an EM xs 301 B 3 4 2 6 7 gf 10 p x10 5 2 C1 Wi 9 5 5 NEGATIVE POWER SUPPLY 330740 330740 2 1 940 1 5 7 50 2292 50V 9572 XC9536 MCL450510W SPI CONNECTIONS POWER SUPPLIES DG201ADY mi DGZ01ADY 10 2331 174 25 Vss x 7 u 158PI 155 1 12 RIS 100K 1 xt gt 5 5 SS 010 4 GSPI 55 1 05 1 8 1A FR t 4 30740 1 EUST 1 4007 PE IU xi 05 OSC_NEG_PS gt 2 pur ovreuri 10 tq m l ug 7 1901 9 22 GENERAL INFORMATION CAST NO USED 5 20v O AN 475K 01 44518M 09 un p n ELECTRICAL SYMBOLS PER E1537 oaw 50V M 30740 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 9 9 05 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS
101. C Return to Section TOC Return to Master TOC o m 2 o 2 5 Return to Section TOC Return to Master TOC Q 2 5 DRIVE ROLL KITS Refer to Table C 1 for various drive roll kits that are available for the POWER MIG All items in Bold are supplied standard with the POWER MIG TABLE C 1 023 030 0 6 0 8 mm KP1696 030S 035 0 9 mm KP1696 035S 045 1 2 mm KP1696 045S 040 1 0mm KP 1696 2 KP 1696 1 KP1697 045C KP1695 3 64A 035 0 9 mm 045 1 2 mm 035 Aluminum recommended for Push Pull systems only 3 64 1 2 mm ALUMINUM FEEDING KIT K2153 1 This kit helps push feeding aluminum through stan 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 Kit includes drive rolls and wire guide plate for the wire drive liner and two contact tips for the gun along with installation instructions K363P READI REEL ADAPTER The K363P Readi Reel Adapter mounts to the 2 spindle It is needed to mount the 22 30 Ib Readi Reels 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 cy
102. D USED R LABELS SUPPLY VOLTAGE NET O Power SUPPLY source POINT 7 COMMON CONNECTION 7H Frawe 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 MANUFACTURING TOLERANCE PER E2058 ON 2 PLACE DECIMALS IS 02 DO NOT SCALE THIS DRAWING TKINFO 0 Sheet No DESIGNINFORNATION REFERENCE EQUIPMENT TYPE Digital Systems 68 2 2004 DRAWN BY JPK z 2 0 27 2000 uS SUBIECT Schematic Digital Power Supply APPROVED SCAENCNE DATET 30 98 DRAWNGN G 3631 SOLID EDGE G 12 POWER MIG 300 us ELECTRICAL DIAGRAMS mI SCHEMATIC CHOPPER BOARD CODE 10562 11098
103. DIGITAL CONTROL PC BOARD 3 CODE 10562 11098
104. E 50 s 8 AD_DATAIZ smi MOSI aig E 5 2 SW 8230 19 VREF 08312 AD DATADI Mlk SANH ele iv TTSK v 00k sur 8 convst DATALI POT CS 1 e 142 ales pas AD DATAISI TPL AD CS 22 9 AD_DATAI6 33v SV SHT 4 RD 086 5W 22 0 xis 087 6 DATAITI A D CONVERSION V 28 5 DATAIBI VAL 088 8 1418 un AD DATAISI 12150 RS m AD_DATAILO SHT 1 SHON 5 5 17 AD DATAILL TS guosanui P 4 a EL EA 100 100 100 100 100 100 100 100 100 100 un SAWTOOTH GENERATOR 12 Sw did m m m a 47 2 28 __ 3 emn SYS RESET EI m e p pa Je 9 S 01 23 50V p 172w 1 24 172w 172w 1 2 172w 172w 172w 1 24 1 24 a as asv B 057 4 051 zv zov BIRPSIR 2 EA T Ex E IV PRIMARY CURRENT SENSE n 5VA RES LFLOW STT SHT 1 C124 ivi AD DATAIO _ 19 peo Tm ask sm 2 033 4 _ gt o o 9 m AD DATAIZ 13 pe T x2 7 RAS pns Lr 5 12 5438 4 R54 R58 amp TUKC 3 x ADDATAM 1 89 YA LAD TOOK TOOK ojoo Hve pridt AD_DATAISI 10 ay RIOB 8106 m A _ LOOV 2 T Li b 100K TOOK AX ib 00K 5 R66 IN
105. E2 E3 E4 400V Q2 From Rectifier sim 3 5 o R12 1 6 16 ie 19 B7 103K 072 Ole V 40V 10V 8 GND R11 iW 52 085 175 GND z R38 Gs Under Voltage Lockout 10 15 5 681 E T NIN 215 681K IN FTPL ES L 1600 R40 lt 15 V 012 022 CO 11 gt X lt X 150V T T 150V 50V LOmH E m p 2 R41 AN 10 1A 03 08 e NM 68 1K 25V 400V i um SIS R42 500V INT NT 9 1 cH lst Rectifier 681K CE E x 019 5 15 1 CA 147 600 50 50V R6 2 7 1217 Output 25V 01 RB 10 0 C2 C3 To Choke 076 3 Qt 18V V R9 a Lo alo C23 E 8 1w 100 EE A2 022 9 150 VREF GND R7 13 O a n 7 G3 RT CT VEC 100 2 6 m 9 5 2 OUT T 4 75 Buses Olea COMP GND Wy 1 16 hi 8 2 Pm R36 leles 2862 ale Nou 221 4700 3 tH o Sg 50V 2 x 221 01 x3 6 V el 5 T 9 Vb 50 10 7 GND alaz C22 C20 C7 LAST NO USED 5 5 330p ve dg cnm GENERAL INFORMATION ME uc tc 50V 50V m S 100V JZ 4 ys 2 ELECTRICAL SYMBOLS PER E1537 ca ede dod m 2 67 18 12 uius la ane CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED 2 2335 7110 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0712 07 6 wr 30V ERE DIODES 1A 00V
106. ER CAPACITOR MFDVOLTS 8514 408104 2811 40 DC SUPPLY FOR LEDB 45V FOR CAN COMMUNICATION G GREEN 3214 318104 sit 1 09 AND LEDIO ERROR CODE LED9 BLINKS ONCE RESISTOR OHMS WATTS 44 810e SPOOLPUSHERULIGUN MOTOR THEN LEDIO BLINKS ERROR CODE ai 76 lt 5 810 U BLUE CONNECTOR PIN NUMBERS 8810 LOCATEDON 7 74 W WHITE EX 12PIN CONNECTOR DIVIDER Y YELLOW PANEL INTHE WIRE DRIVE PROVIDES BRAKING OF THE LOCATED INSIDE THE COMPARTMENT NEN PC BOND SPOOL GUN SPOOL PUSH PULL GUN 6 PIN FOOT COMPARTMENT P C BOARD MOTOR CONDITIONS PLUGGED ONTO THE SCHEMATICL 120812 THE SIGNAL FROMTHE 777 FRAME GROUND FEEDHEAD BOARD FOTENTIONETER gt EARTHGROUND 88 vw 8 8 8 LABELS THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC THE INFORMATION ON THIS DESIGN INFORMATION REFERENCE PRINT IS FOR REFERENCE EQUIPMENT TYPE POWER 300 SUBIEC MACHINE SCHEMATIC REVISION CIRCUTRY MAY BE DIFFERENT ENGINEER JzuckeR _ SCALE none APPREMhe Creation O CT CRN82923 8 DISPOSITION DATE INBER FROMAN ACTUAL MACHNE APPROVED
107. ERENCE L11756 SEEN RENG Mee UNLESS OTHERWISE SPECIFIED CAPCITANCE MFD VOLTS RESISTANCE OHMS INDUCTANCE HENRIES Return to Master TOC SPI DISPLAY L11757 1 Return to Section TOC FN B NOTE ON CAUTION THIS DEVICE SUBJECT DAMAGE STATIC ELECTRICITY we pee SEE E2454 BEFORE HANDLING DO NOT COAT WITH ENCAPSULATION MATERIAL N B USE ITEM 2 TO STAND LED1 LED2 LEDS AND LED4 FROM THE P C BOARD THERE MUST NOT BE MORE THAN 020 GAP BETWEEN SPACER AND BOARD OR BETWEEN SPACER AND LED ENCAPSULATE P C BOARD SPACER AND LOWER HALF OF LED DISP1 AND DISP2 MUST ALWAYS BE MATCHED BY VENDOR DO NOT MIX DIFFERENT VENDORS ON THE SAME BOARD ASSEMBLY ENCAPSULATE LOWER HALF OF DISPLAYS ONLY FACE AND UPPER HALF MUST BE FREE OF ENCAPSULATION CONNECTOR MUST BE GREASED WITH ITEM 3 PRIOR ENCAPSULATION BUY AS 111757 1 1 IDENTICATION CODE O o 5 5 PEN 9 gt 212 5 5 ENCAPSULATE WITH HUMISEAL 142714 PER E1844 OR WITH EQUIVALENT AS APPROVED BY LINCOLN ELECTRIC COMPANY 2 COATS BUY PER E3867 TEST PER E3856 D MISCELLANEOUS DET tee SPI DISPLAY P C BOARD ASSEMBLY DOCUMEN MATERIAL FOLERANCE t AGREE ENGINEER WITH PUBLISHEO STANDARDS NOT SCALE THIS DRAWING L11757 1 A ON 2
108. G CONTROLLED CHANC MANUFACTURER No GENERAL INFORMATION CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD ELECTRICAL SYMBOLS PER E1537 ADASH SCROLLS 1 COLOR CODE ALONG DISPLAY BOARD B BLACK 381 182 TAKES ABOUT 10 SECONDS w WHITE R RED LOCATED ON FRONT A A 1 1 U BLUE OF J1 986 MAIN TRANSFORMER LOCATED ON MACHINE S BASE STORAGE SIDE IF LAST MODE WAS LE LAST was IF LAST MODE WAS SYNERGIC GATED ON TOR OK ANP LEDILLUMNATES WFS AND VOLTAGE WFS AND TRIM MAIN TRANSFORMER OUTPUT WITH CORRESPONDING VALUE LEDS ILLUMNATE WTH LED s ILLUMINATE WTH RECTIFIER LOCATED NEXT MAIN TRANSFORMER RIGHT DISPLAY OFF CORRESPONDING VALUES CORRESPONDING VALUES QUIT ON WIRE DRIVE SIDE Return to Section TOC Return to Master TOC CHOPPER P C BOARD CURRENT SCHEMATIC MIS792 1 TRANSDUCER e 2400 100 LOCATEDON CHOPPER BOARD ASSEMBLY LOCATED MACHINE S BASE WIRE DRIVE SIDE LOCATED ON TRANSFORMER BAFFLE FAN STAYS FOR 5 MIN AFTER ALL FLEX PAST GUN TRIGGER EN AA SHIELDED CABLE 15 CLOSED FAN RELAY 6800 76 DIGITAL POWER LOCATEDON SUPPLY P C BOARD TRANSFORMER SCHEMATIC 63631 BAFFLE 241 lt su fx HET 5 ya 208 CONTROL SUPPLY 3 542 L CONROLBDSUPPLY COMVON LEDI RED Return to Master TOC ALL 3 LED S ILLUMINATE AT THERMAL TRIP
109. ID CONTROL i 107 415V 405 E H POWER SUPPLIES 5 VOLT SUPPLY 4 2 pi 4 JE 1 mi 8 15 VOLT SUPPLY APO VLA vN 200 VOLT SUPPL 4 3 4 SINSE SELECT ee 9 a o mi 15 u DNLY al g i vss A be gt se 7 VOLT SUPPLY xs ic Ds E xa y Les m2075 soe JE we m OL az nu el mulz alz 25 CIS 5 VOLT SUPPLY 5560 NE s WI aut SV sq SW SV 40624 SPV 14 YEL MIISA EE e SEE 55 r z 2 T rae 4 P ad E t 2 gt Ven E bala DM LSY E Y SS SS R div i ELECTRODE SENSE LEAD amp qe u h asv CINTROL lt a 287 e Erin po Ri m XS g 8 4 ww Zire 20 GENEAAL NF TAMAT IN NIE ns qr Al 261 plaa d ELECTI DhL SYMBOLS PER EIS27 E e k N pur gt 21 12 MED 1 477 994 UNLESS OFHEAVESE GPEZZFIEDI MITA gt 7 VREF 5 p xm Alerser 8 Ohms L L UNLESS s 0 La IXE al 7 51 zu x5 E fA444V LALESS OTHERWISE ECIFIERI D LK vee DE i EN zu CE x Li fna Ter FILTRE TET E 57 mb za Lay p pje 7 SL
110. ING STRE 35 3 18152 18 SHT 1 1 0141 1 0184 A n CST 142 181 R W SHT 1 ADCINS WRH SHT 2 55 1 ESI SHT 1 1 0142 1 78 5 Sii FPGA CS 207 cca Parka 160 05 _0101 voteo ADDRI111 ADCING BR 79 x22 9L 0 t DSP CLK 2 1 0 700 157 08 019 146 1 0146 1 0179 119 ADORI101 ADCIN7 PWM1 CMPL gt 5 1 ga 91 95 15501 6 155 05 _0181 147 178 ADDRISI ADCINB IOPA3 PWM2 CMP2 7 SHT D 7 155 1 Ws xU ADE 20 AncINS IDPA2 8 gt SHT 1 SGCK4 SHT 1 5 1 0148 140177 S A LAD 97 1 183 MOSI OUTPUT ON 149 176 DATAI101 SHT 3 ADCIN10 on Tios CLK 8 5 1 53 1099 0765 DATAI I 88 ADCIN11 5 L8 mE sHri sack PGCK3 SHT 2 SHT 1 1 0150 1 0175 AM MIT 5 106 FPGA_RESET SPLCS2 174 DATAIBI WM6 M MODE PROGRAM SHT 1 SHT 1 1 0151 10174 ume eene 100 Socr pone 104 FPGA DONE En 152170152 2 aa DATASI 186 1 0186 n M 9 sm Ax Sd secoli dmi 5 1 1 1591 159 vor 1 ADORIS DATAA 187 0167 1002051205 ADDRILI PWMG CHPG IOPBl 292 MOSI_B 64 LUC mm FPGA_BAD gt SHT 1 SHT 1 5 50 1 0161 1 0169 169 ADDRI6 DATALI 188 1 0188 1 0204 204 008 2 ADCINIS PWM9 CMP9 IOPB2 SHT 1 1 0162 1 0168 168 ADORTI 21 189 1 0189 1 0201 201 AODDR 31 4 MS320F240 16
111. ITEMS BELOW REFER TO ELECTRONIC COMPONENTS DATABASE FOR SPECIFICATIONS Ci 25024 7SMT CAPACITOR SMD TANTALUM 47MF 20V 1096 8 7343 C2 C3 C4 C5 C11 C12 C19 C20 525020 35 CAPACITOR SMD CERAMIC 0 IMF 50V 10 X7R 30805 DISP2 517395 9 LED DISPLAY 7 SEGMENT CC 4 DIGIT 137 __ 1 51824810 _____ CONNECTOR MOLEXMINI PCB 10 PIN LED1 LED2 LEDS LED4 113657 6 1 101 5 LED6 LED7 T13657 14 LED 1 1 3 4 AMBER HIGH INTENSITY R6 R16 825000 15015 RESISTOR SMD METAL FILM 1 10W 1 50K 196 80805 R9 R10 R11 R12 R13 R14 25000 12125 _ RESISTOR SMD METAL FILM 1 10W 12 1K 196 80805 25000 26708MT RESISTOR SMD METAL FILM 1 10W 2670HMS 1 50805 1525000 RESISTOR SMD METAL FILM 1 10W 1 00 1 50805 S25000 0ROSMT RESISTOR SMD METAL FILM 1 10W 10 00HMS 1 S0805 25000 47515 RESISTOR SMD METAL FILM 1 10W 4 75K 1 S0805 525000 47525 _ RESISTOR SMD METAL FILM 1 10W 47 5K 196 50805 517900 85 IC SMD CMOS INVERTER SCHMITT HEX HC14A SS 517900 265 15 5 08 5 0 8 6151 55 817900 285 IC SMD CMOS HEX INVERTING BUFFER 3 ST SS _ 17900 108MT IC SMDCMOS REGISTER SHF f S PI SO 8 BIT SS 520496 15 IC SMD CMOS DRIVER DISPLAY LED CC MCU Return to Section TOC Return to Master TOC REF
112. IZI SHUT DOWN 0095 7i DATADI gt 7 ADDRIGI 117 012 PDAS ADORITI DATAISI d E 10 E OS E POAG Hs 0091 DATAIGI HCPLOGOL 2 4 STEP 53 119 ADDRISI DATAITI 3 0012 lt 7 WFS_POT 34 paso ADDRI10 DATAIBI 35 ADORI1 com DATA DATA 9143 Lo pe MOTRV_MON 69 70 71 64 65 66 E E Es TRIEGER POAO en 0 POAL 2 82 R W 113 CSB 114 50 115 51 116 CS2 DATA2 DATAIS ook Shook 475 biw 01M DUAL_PROC ADDRILI x32 DATAISI 36 ADDRUI ADDRIZI Ej ADDRISI 1 D ADDRI13 TE28F800 DATAI11 38 pop ADDR4 L6 5 21 39 pops Anops L7 ADDRIST ADDRILSI DATAU3I 8 POSITION 6 Anope L8 ADDRII ADDRI16 REED SW C p L2 ADORTI ADDRILTI 160 c ANRXQ x appre 2L ADDRIBI ADDRI8 ADDR9 22 ADDRISI ADDRISI 1281 mo Rx 68376 AnDro 23 20080 p 24 ADDRI11 TXD ADDR11 R W 1 asy sm SPI I
113. K 100K gt V sov vi M M i Ve 10K CURRENT NODE CONTROL DISABLE THE 5V A 18 FETS AS SOON AS PRIMARY CURRENT 5V O o SHT 2 15V lout Vinx0 99mA 15 GREATER THAN A REFERENCE LEVEL 15V OJO glen 330740 gt I J 056 5V Ve 8 RIAL 02A n NE ca 4 4 0 1s SHT 2 5V R69 m 175 50 50 Tu 1 KT 619 si jg sva S xB x20 i CURRENT FEEDBACK _ 0 SHT DCO 15V INTEGRATOR 33 02A 330740 ee 330740 330740 2 2 E WM F 2 sv VC sv VC 50V Nc 1 29 STUP 4 R127 SSS AK 45 gt 1 R73 51 100 t 5y p MA 4 Se 330740 6 5 R122 ph J9 67 1 m 15V 4 yaw T e m Rize ira y 2 5 6 9 c F 30V tio 225 rd CMM TTK T D SECONDARY CURRENT SENSE a tc 100K 1 24 1135 8 100 T 330pF S VHCLAD 2 06409 1000 332 5VA 6 RTI I 8 CLR CAP 3 8 8403ARU10 200K 1 28 Hao os 6 R210 E59 R60 23 XE 5 24 d 29 16 TTK 3 lt 2 lt 3500 VOLTS at R x EN 95 OHM 5 CONNECTOR 2 u UM lt 5 3 SHT 8 EE UT xs 15 x19 gt RY x8 1 R138 90 PA sov 22v BV SHT 4 MSELL IDEAL VOLTAGE R124 R125 RI18 8206 275 v Le por 100K T50K T50K 45VA E 3 sv vc SHT 4 MSELEN R120 4 5 30 76K
114. LED s ILLUMNATE WTH LED s ILLUMNATE WITH MAIN TRANSFORMER INPUT RECTIFIER LOCATED NEXT TO INTRANSFORMER RIGHT DISPLAY OFF CORRESPONDING VALUES CORRESPONDING VALUES QUIPUT ON WIRE DRIVE SIDE Return to Section TOC Return to Master TOC CONNECTED FOR 230 RECONNECT PANEL mum R E CHOPPER P C BOARD pa RI SCHEMATIC 1979241 2400100 2580 LOCATED ON f CHOPPER BOARD np ASSEMBLY LOCATEDAT MACHINE S BASE WIRE DRIVE SIDE LOCATED AT BOTTOM OF FAN STAYS ON FOR 5 MIN AFTER BOARD COMPARTMENT FOR ALL FLEX AND LAST GUN TRIGGER WHEN 2 4 IS CLOSED DIGITAL POWER SUPPLY BOARD FAN RELAY 6800 75 SCHEMATIC 63631 LOCATED ON TRANSFORMER p 5 3 350 LEDI TOROID Return to Master TOC ILLUMINATED LEI INDICATES VOLTAGES ARE BEING SUPPLIED TO 42 SPI FLEXSHELDED CABLE SUPPLY ILLUMINATEDLEI LOCATED ON LOCATED ON INDICATES VOLTAGES ARE SECONDARY CHOPPER BOARD BEING SUPPLIED TO J43 WINDINGS HEATSINK RS232 SUPPLY ALL 3 LED S ILLUMINATE AT THERMAL TRIP Return to Section TOC SCHEMATIC 111108 SPI DISPLAY VOLTAGE FEEDBACK CAN COMMUNICATION FOR WELDFILE SUPPLY DOWNLOADE LOCATED ON TOP OF P C BOARD COMPARTMENT 88 R232 PWMCONTROLLED LOCATED INLEFT SIDE OF CONNECTOR me i i CONTROL 6 5 VDC WHEN GAS P C BOARD
115. LIES amp S 4 75K 44 X28 axo 22 LEDIO 5 ES 3 6 TA T GCAN D 0 MODEL ED 24 12 5CAN SHT 1 lt l INT Ucc 2 p252 9 5 p24 13 i 03 asv o gt SYS RESET 2j majoaisa A v SHT 1 RESE P23 60V 3W 8 c 2527 22 15 STATUS i bons E SCAN 150 r SHT 1 WRH P27 p2ipe A ADDRILT ried 8551 Jy ADO CLOCKOUT SHT 1 4 5 3 READY MISO 28 4 ADORI3 2 02 ___RW_ 1 15 STATUS LED 475 1 S 221 ADORIA BB DATAIBI s ADDRISI Ju pul DATAISI CIRCUITRY ZI yos AD4 MOSI P11 AD9 3 DE B T BUSS H 1 ADDRIGI ADS PL2 AD10 DATADO ajo 485 6 AD6 SCLK P13 A011 Bak 2 is ADDRIBI 2 bs bortis os 07 PLA ADI2 05 10601 D 18xrAL1 P15 A013 DATAS n Mv 5 082 N 085 150 1 141 2 62 62 8 16 2 XTAL2 P1 6 AD14 3w Yt PLI ADLS DATAUSI 57 GREEN V x 1 8 RE rd ADDRIL 19 m ae EM ae DATAIO 151 Jir v JSON GCAN 50 50 v 026 400 DN CAN COMMUNICATION CIRCUITRY 8 2428 400V 100 121 18 01 8 __ 93 011 50 X MUN CAN COMMUNICATION CIRCUITRY 3W 5V 5 GENERAL INFORMATION LAST NO USED J8 O O lt lt ELECTRICAL S
116. Master TOC X PEN elg 5 2 21 Return to Section TOC Return to Master TOC B 10 4 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining ring groove on the spin dle FEEDING WIRE ELECTRODE A 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 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 1 Turn the Readi Reel or spool until the free end of the electrode is accessible 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 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
117. Molex plug cavity 3 Perform the resistance tests in Table F 1 TABLE F 1 CHOPPER BOARD RESISTANCE TEST TABLE Test Point 5 B6 4 5 400 ohms Higher 4 B6 B2 B3 4 B2 4 400 ohms or Higher B4 3 200 ohms or Higher 3 4 400 ohms or Higher FIGURE F 3 CHOPPER BOARD CONNECTIONS 977 1 B4 qe d B2 iu B5 E 72 689 B3 B6 POWER MIG 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section 5 Return to Master F 18 F 18 TROUBLESHOOTING amp REPAIR CHOPPER BOARD TEST continued FIGURE F 4 J6 Dooo a 607 z Do 1 OOOOOO O0 c PWM SIGNAL TEST 1 Locate 607 7 6 and 615 15 6 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 1 8 2 VDC 20 KHZ POWER MIG 300 LINCOLN 19 19 TROUBLESHO
118. NAL DISCHARGE CY 300 CHOPPER qe ee GS B1 _ 4 ee B2 5 77 S 642 T Ge e C1 B3 B6 J99 PROCEDURE 5 Using the resistor and jumper leads CAREFULLY discharge the capacitor terminals There are 5 A WARNING capacitors NEVER USE A SHORTING STRAP FOR THIS PURPOSE DO NOT TOUCH THE ELECTRIC SHOCK can kill TERMINALS WITH YOUR BARE HANDS High voltage is present when input power is applied to discharge the capacitors hold the jumper leads to the machine the following terminals for a minimum of 10 seconds each See Figure F 1 and the Wiring Diagram Refer to Figure F 1 1 Remove main input power supply to the machine C10 and C11 B1and B2 2 Liftthe hinged right side case cover B1 B 3 Using the 3 8 in nutdriver remove the bottom right case cover C8 and C9 84 and 5 4 Locate the Chopper Board with capacitors mount ed on the center of the machine base right side Using the volt ohmmeter check the voltage across See Figure F 1 terminals 1 and B2 and B1 and 85 and B4 and B5 Each reading should now be zero volts POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC F 14 F 14 TROUBLESHOOTING amp
119. NBACK s M esser is 1 7 SPOT LY SELECT T 2 AL 5356 gt elg 5 2 21 PREFLOW POSTFLOW Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 o 2 5 Return to Section TOC Return to Master TOC Q 5 6 MULTI PROCESS PANEL FUNCTIONS Weld Mode Setting the Weld Mode is selecting the proper program from the ones available in the machine s memory for a particular welding application The table on the right side of the front panel 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 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 SE
120. NTERFACE ii d unus PCS3 00812 R W INV 28 PCS2 ADDR13 26 ADDRIL3I 45V 13 PCSi ADDR14 27 ADDRIL 4T 50 00815 28 ADDRITSI SCK 0 16 29 ADDRI16 vost BEAD 64K X 16 SRAM 32 ADDRI18 SCC MISO ADDRI8 ADDRULA91 12 0081191 51 vec m CLKOUT ADDRIS 123 28 50 XTAL ADDR20 Bucs WP GND ExTAL ADDR21 124 VPPOFF ADDRILTI MS 00 22 125 ADDRI16 5 AQOR23 126 ADDRILSI ARC_V_NEG A_POSITION 128K X 1 SERIAL EEPROM 6 Return to Section Return to Master TOC 1 2521 55 3 SPICSI 4 SPICS2 25128 5 SPICS3 ADDRIL4 is 6 BMOSI CPLD ADDRI3I di 7 BSCK ADDRI2 Alt 1 0182 1 0181 A10 1 0282 1 0281 ADDRI10 DATAI101 1 0482 1 0481 ADDRIS AB 9 1 0782 1 0681 ADDRI8 8 1 0882 1 0881 ADDRI7I DATALUI 1 0982 1 0981 MOTOR_ON A ADDRI6 DATAI6I OUTPUT ON 1701082 14 1981 5 ADDRISI DATAISI 1 01182 1 01181 ESOS DORT 1 01282 x35 1 01281 100M ADORI3 DATAI3I 1 01382 1 013 1 m soL ADDRI2I 15616416 12 1 01482 XC9536 1 0141 150K ADDRILI 1401582 10015811 od CS2 DATAIOI 1 01682 1 01681 652
121. OTING amp REPAIR CONTROL RECTIFIER TEST WARNING Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter 3 8 Nut driver POWER MIG 300 Machine Schematic olo E e olg iz 8 e 5 5 ply Return to Section Return to Master TOC POWER MIG 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E olg iz 8 e 5 5 ply Return to Section Return to Master TOC F 20 F 20 TROUBLESHOOTING a
122. OTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check for loose or faulty con nections of the heavy current carrying leads See Wiring Diagram 2 Perform the Transducer Test 3 Perform Output Waveform 4 Perform the Output Rectifier Assembly Tests 5 The Control Board may be faulty Replace The output voltage and wire feed is present continuously or pulsing when gun trigger is NOT activated Remove the gun If the problem is resolved the gun trigger cir cuit is faulty Repair or replace problem persists when gun assembly is removed from machine then the problem is within the POWER MIG 300 l Find J85 on Feed Head Board and unplug If the problem still exist Feed Head Board may be faulty The output voltage is present con tinuously when gun trigger is NOT activated The wire is not feeding l Find J6 on Control PCB and unplug If output voltage is not present change Control PCB 2 Perform the Chopper Board CAUTION If 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 POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC e olg iz 212 515 Return to Sect
123. OUT SHT 1 01 o ZZK 6 91 lt lt 7 LADJTN 2 INPUT FROM 2ND LEM V Ole a ae 81 i 06 5 v LE xi xn R102 02 121K SS 8 7 ogg H 52 o 2 100v 4 1016CSB 6088 Kh VD M sra Ve STT CURR AD_DATALOI 5 rois a 5 4 7 1816 9 6 um 2 AD DATAMI 4 peii AD7945BRS 9 V n 1 500 12 2 wT 10K g V N V 8 5 ky 5v SHT amp V D m PRIMARY CURRENT SHUTDOWN 03 09A 20 Mid x32 32 PE DUCER 5 54 SIGNAL IN RIOT R109 A 45VA 5VA LV 400A OUTPUT T UT c2 A 5VA 15V CURRENT TRANSDUCER INPUT 9 VOLTAGE cl BU 2 d uu oe i 1 gt R26 7 nlt TTK 332 xs A 18 R23 R27 FSK 61 enol 330740 1 V 15 b 5u TSK 5517 8 R62 R59 8 Rad 3 IN QUT gt SHT 1 xi2 dcc x 2 x aii a 1 LL gm 100 Zi 3 71 100 N 6 01 501 501 2740022 2 M SHT 4 SEER D6417 1 00K TOK a7 4 y 5 ouis xd 21 9 2d Us _ uh 034 1 5 ZR ezopr E 15V N 02 50V 101658 II LI R CURRENT LIMIT Qva ea SIL 175 4 07 27658 0145 19 BAO3ARUO __________ SHT A 50 g Ritz X6 A 150
124. Operation section 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 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 c Slip the appropriate gas nozzle onto the nozzle insulator Adjustable gas nozzles are available with 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 Choose the gas nozzle as appropriate for the GMAW process to be used Typically the contact end should be flush to 12 31 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 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 To help prevent feeding problems clean cable liner after using approximately 300 pounds 136 kg of electrode Re
125. PLACE DECIMALS IS 02 SOLID EDGE EN 168 Return to Section TOC Return to Master TOC NOTE Lincoln Electric assumes no responsibility for 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 LINCOLN amp ine LINCOLN machine POWER MIG 300 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 Return to Master TOC 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 Return to Master TOC SVM Number Your Company Your Name o 5 50287 01 99 Return to Master TOC LINCOLN 5 POWER MIG 3
126. PLY CONTROL BOARD s 185 lt RECOGAIZES 46 lt 8 8 3 82 126 TO PONER FEEDHEADBOARD 3734 diu e BLINKING IF THERE 15 am e ERROR et an Au ea PANEL ENCODERS une WESAMPS VOLTS TRIM Dit g GREEN 7 PIN AVPTROL Et I DIP SWITCHES C peres re ut USED ONLY FOR 1 SPOOL GUNFLSHEULL SPOOLGUN PUSHPULLPOSITION ETERNAL DIODE 716 187 amp GREEN DIVIDER PUSH PULL LOCATED THE RIGHT OF WIRE USED FOR MOTOR LED REDLEDS ARE SOLID AT age PANEL INTHE SWITCH DRIVE ASSEMBLY ON CENTER PANEL THEN BLANK 35 WARE DRIVE 858K 8 85 lt 588 815 COMPARTMENT 8511 4 lt 1085 lt 8510 10 85 lt 859 985 lt 857 7 5 lt ojo Els 5 5 ply a LOCATEDINP C BOARD LOCATED INP C BOARD 5598885 CENPARTNENT CONTROL P C BOARD LED LEGEND CONPARTMENT 9995899 15V POWER TO CONTROL BOARD LEFT FRONT SIDE vvvvvvy LED2 15V POWER TO CONTROL BOARD vvvvvvy LEDB 45V FOR SPI CABLE SPOOL PUSH PULL GUN 5 14185 lt 8 BE 8 8 82 82 REACH ERES LED4 15V FOR SPI CABLE BRAKE SIGNAL 846 6 84 lt BSSSREKS LEDS 45V POWER TO CONTROL P C BOARD OVOLT NOTOR BRAKE o sysIGNALVARIES WITH LEDS 45V FOR 5232 CONNECTOR LEAD COLOR CODE COMPONENT VALUE UNITS 8464 44 6 810 LED7 A FATAL ERROR HAS OCCURED B BLACK i REMOTE POT WIP
127. PPLY SOURCE P42NF 6 Di UK ips 20208 021 4 039 vi com 57 CONNEC TEIN TM LOW EON ZL T o tts ah d 5 FRAME DINNEETIUN 186 ME 2 DROLNI CONNECTZON 2 Lad 93 gt 27400 94 1 DE 54 MI THIS ODCUNENT CONTAINS PRIPRICT AR Y NEPRIATIDN DWNEI L BAL INE AND M COMMUNICATED o 5 m baw i gt 2 um PADPRIETARY amp CONFIDENTIAL rites ER Dan FOR ANN THE EXPRESS WEITEN DF LINCOLN JNE e SU 58 m zik 52 2 7 pug BN Cu H8 m CUT DESIGN peFenence EQUIPMENT TYPE COMMON DIGITAL CONTROLS PAGE 42 DF 92 BENT POWER 31 uo s e ss i Her 22 5 35 WEHI INTERCHANGE SUBJECT c di M uM oum SEHEMATIL 7 amp ARCLINK FOR REVISION 5 Sas aAA ES EON ANS er ste Tus HRTERSAL pa POEL 3BR3 1ED A HAVING CAMMON ZIDE NUM ER ORAWINE 05 12 2063 nungen CAMS54L5 d c NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 POWER MIG 300 oe ELECTRICAL DIAGRAMS eis SCHEMATIC SPOOL GUN PC BOARD CODE 10562 11098 SHEET 1
128. R126 R130 7 8126 R115 100K 1 71 48 054 TEK 100K 3 1 lt GAIN lt 11 V Ve 5 70 cse 01 M 400V t 15V eee 440A xu g R121 gt 330740 150K 049 SNO 677 ps olo rr T 2 AU 25 70 ARCVOLTS GENERAL INFORMATION LAST NO USED 3 10 O O or 037 2 5 ELECTRICAL SYMBOLS PER E1537 Re UA thw thw 1 2W 100 050 TPS CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIE EZ E 02 E RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 0 Ap 7V VOLTAGE FEEDBACK DIODES 1A400V UNLESS OTHERWISE SPECIFIED 8 SUPPLY VOLTAGE NET C35 C36 wo X C38 c3 NT L 190pF zm 150p 150pF gu 150pF AN 5 POWER SUPPLY SOURCE POINT S D 1000 100 1000 1000 15V ils gl S 175 Sus FILENAME 63789 10 1 2 FRAME CONNECTION gt 036 038 042 000 amp THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC LS EARTH GROUND CONNECTION o f 51V P Zu vool AND IS NOT BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF LINCOLN ELECTRIC CO 1 2W 1 2W 1 2W 1 28 TURN OFF_N uF 3 3 sly 9017 Reis UNLESS OTHERWISE SPECIFIED TOLERANCE _ te THE LINCOLN ELECTRIC CO 80 INVERTER WELDERS 55 ON HOLES SIZES 2056 m No en PLACE BECAS Je o 6 2 2000 CLEVELAND OHIO U S
129. R78 13 30740 ZZIK RTE 50740 100 01 R26 ojo 55 1 55 1 aS 3 cst R28 SPI CONNECTIONS 014 01 T um 10 0K sov 500 MOSI CPLD CB Q6 4 07 1 057 2700 bsa 2225 2 32 u 10 Vespi E 40 soov SCLK 8 Ral lioa 1 018 35 50 2 2 1 028 3e R38 7 gt 17 SPOOL HC14AD 3 eir 57 GUN BLOCK 1 n 5 BLOCK 2 38 075 100 022 ddr 6 Vois gs TZIK 5 1 05 1 058 225W id 01 9 m HCLLAD 106A 1 068 24 55 100102 _ se Veser cs3 6 2X RIL 1 2 IVSA Sy 1 020 2 2 PwM OUT um 252 13 03 1 030 26 gt POT DETECT 45VREF HCL4AD INV CSl 14 10040127 gt OSC_NEG PS 18 055 1 050 232 3 4 2 5 RBL INPUT OK 19 FTP amp FIPS FTPS 5 2 INK 2 nuni EN SHIFTI 201107 BLOCKS 76 OF SPOOL 1 0 30740 02417 aspi V HCL6AD EN HBITI 22 GUN PO 30V 5 024 Q 462 R90 INSEL 6 ens LM uw E E ys 76 007 C gt KO 1 0 GCK2 W T 7 O 014 1 5 Bop 1 0 GCK3 as 5 01 T5K 0 8151 IMs d ie ites 954 MOSI 92 RES 13 qr 12 4010 8752 IN 50 05 IZIK 39 v o ssn eser V to HCLLAD v miso 1427 SR sse 55 1 o gt MISO CPLD POT_OETECT D
130. 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 POWER MIG 300 LINCOLN 8 Return to Section Return to Master TOC Return to Section TOC o Fle 2 Oo G gg 5 2 Return to Section Return to Master TOC Return to Master TOC F 15 F 15 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER TEST continued FIGURE F 2 MAIN TRANSFORMER TEST POINT LOCATIONS LOCATED ON FRONT OF MACHINE S BASE
131. RETURN MAIN MENU SVM160 B POWER MIG 300 Apri 2005 For use with machine Code Numbers 10562 10952 10958 11000 11097 11098 Return to Master TOC View Safety Info 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 Return to Master TOC View Safety Info Sj TSN SNe Ss put gt 2 o 2 gt E SERVICE MANUAL Sau i D v gt p E tc NCOLN 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 View Safety Info Return to Master TOC Return to Master Return to Master TOC Q 5 Return to Master SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of it
132. ROLS THE SPEED ACCESS THIS CONNECTOR s ESPOO BY REMOVING THE WIRE PUSH PULL GUNS BY READING THE POTENTIOMETER VARIABLE VOLTAGE FEEBACK COMVON 1SVDC LEMSUPPLY com FAND 3234 SPOOL GUNPLSHPULL MOTOR 50INMN 4 323 3323 gt 3233 5voc 4034 6 MOTOR GEARBOX TACH DRIVE ASSEMBLY SPISUPPLY HNO ayo Dit l 26 sonny SvCTACHsUeLY Y 401 27 4VDC 700 INMN TACHsIGNAL RS232SUPPLY _ 5 0 8SECONDAVERAGE CURREN D 1 4067 HC NSP3 BOARD 35 e SCHEMATIC 111612 e MODES AND PROCESSES ee 5 SOFTWARE SET MESURER TOU JUNPER ARE SOTHE ALLOWS THE SELECTION OF DIFFERENT 120Hz G 50INMN CONTROL BOARD 1 6 700 INMN 4 INMI RECOGNIZES uj LOCATED ABOVE WIRE GUNTRIGGERSUPPLY aci THATITIS DRIVE ASSEMBLY ON 614 THIS LED WLLL CENTER PANEL BLINKING IF THERE 5 CAN COMMUNICATION SUPPLY 45V ANERROR a 110 GREEN wore 76 ume 1101 une EMOTE amp 3 Gen AON 2m IL 7T 73321 1032 SHELIED CABLE DIP SWITCHES LOCATED INLEFT SIDE OF E DIP SWITCHES TRIGGER SWITCHES MUST P C BOARD COMPARTMENT SWITCHES MUST BE 4 uec 3324 34 73243 INOFF POSITION TRIGGER 4 GREENLEDs REMAIN amp REDLED s ARE SOLID AT SOLIDGREEN POWER UP THEN BLANK
133. S A suayect SCHEMATIC DIGITAL CONTROL C N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE 3 PLACE DECIMALS IS 002 8 5 2000 04 WITHOUT AFFECTING THE INTERCHANGEABILITY OF COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES IS 5 OF DEGREE PG SCALE _NONE SHT 5 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING COMMON CODE MATERIAL TOLERANCE TO AGREE DR 08 02 2000 5 no 63789 100 NUMBER WITH PUBLISHED STANDARDS 7 o oc MODEM NOTE This diagram is for reference only It may not accurate for machines covered by this manual LINCOLN 59 ELECTRIC POWER MIG 300 Return to Section Return to Master TOC Return to Section TOC 2 iz 8 JE ply Return to Section Return to Master TOC Return to Master TOC G 12 SCHEMATIC POWER SUPPLY PRINTED CIRCUIT BOARD CODE 10562 11098 LINCOLN 59 ELECTRIC ELECTRICAL DIAGRAMS EN 170 10 55 voc Operation m 0 lt lt Machine Control Shut Down Capacitor en Undervoltage Detect lt 30VDC 15Volts 750 Amp gt gt
134. SCRIPTION 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED Resistive Load Bank Calibrated Test Voltmeter Calibrated Test Ammeter O10 O10 a gt 23 e 5 5 ply Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo e iz g 2 5 Return to Section Return to Master TOC F 53 TROUBLESHOOTING amp REPAIR VOLTAGE amp CURRENT CALIBRATION PROCEDURE continued CALIBRATION CHECK CODE 10562 NOTE Before attempting to calibrate the voltage 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 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 1 4 Release the mode select switch toggle the mode switch one more time then toggle the MODE SET switch until the 5 panel 9 reads 200 Disengage the idler arm on the wire drive so no wire will feed 5 With the machine
135. SLNSNOdWOD JINIS 02 3181293 13 N 109NI 1 SHL 30 NOISSIWH3d SS38dX3 SHL 1 3 YO 035072510 38 01 LON SI ONY NOLLO3NNO2 HLHV3 702 91919373 102 11 8 NOILYWHOANI 1 4 5 191 02 133HS SIHL NOLLO3NNOO LU NOLLO3NNO2 NOWWOD A LNIOd 324105 H3MOd Q 33 29 EAD teil V 031319345 3SIMH3H10 SS3 ND 007 3001 1 0 613891 031419395 3SIMH3H10 5531 1 7 5440 SHOISIS3H 0315419395 3SIMH3H10 5531 0 A05 ZZ0 044 58401129492 46613 334 5108445 1991819373 035 LON ue 4 gasn ON 1597 NOILYWYOSNI 1VH3N39 aasn LON gt 2000000 01 QHVOS 1459 sg 02 Dx 1859 5 se n L 5 5 Sz LT ONS AOS 9ES6IX AOS A0S AOS H3000N3 AOS 145 5 7 70 to eto V Ty 5 2 2 12 9 Sy 92 SE ST 22A 22A 77 2 Z D 2 o 1459 1955 2 MIO 4 MI 2x 9u 9 ES 008 H3002N3 62 71 5 lt 35 2 3 2 01 123 02 teer tc QV 12H Mo g fu lt oi 2X at 35 253 5 Qv 12H Mto T MIZI 5 2 E 162 lt gt 192 osiw MIO g cc 9 1 Mz au 8 se E Sw 9 101 0 m 001 MTO 5 MEZT Y 7 zx gu
136. SWI3I 9 137 07 x22 M z 1 097 1 0137 OSP_DIB 19 119 PSWIZI 98 136 08 x 1 098 1 0136 05 019 22 TMS320F240 91122 O m S 3 8 Pswit 991 099 1 0135 135 05 01101 23 123 5 01 100 13 puo 05 _ 0 15 1 0100 1 0134 DSP Dii E 124 cla 3 SELEN 101170101 vora 33 05 0021 29012 12 125 0 1 16 PSWIOI TUI 1071 0107 1 0132 132 DSP Di13l 26 126 DSP AL131 rei al 26 109 129 _ 31 rr o vois 5 004 127 5 2 15 PSWILI 110 128 AD_DATAIL21 3 oO oc 1 0110 1 0128 05 _ 115 2 DIS MSB AIS MSB 128 5 _ 5 E gt TPUGI vmos t sim 5 55 1 15 1 3 14 PSWI2I o oe 1131 0113 1001261126 05 _0111 olo PSWI3I 9 os 1 0125 125 6 vor 12 05 _01131 5 12 PSWIAT FUNCEN 116 123 DSP DI151 SHT 1 lt 1 0116 1 0123 DSP BIO 117 122 05 004 5V 7 01021 2 01031 2L pios 11 20 pios L 2 0106 2 0107 1 PSWISI CER vo 1 0122 02 02A 02A 02 02 02 E lt OSP_READY 119 1 0119 1 0120 120 05 _ 70V 70V 70V 70V 70 70V 1 gt 0 PSWI amp I ME 3 3 3 3 3 3 8 o 9 PSWII re i i gt i 6 E i LU s 162 Bg asl 4 16 ml J3 83 R224 R263 4 x33 5 00 01W 33 EMI
137. T 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 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 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 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 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 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 OPERATION B 6 Run In 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 t
138. TALLATION 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 Return to Section TOC Return to Master TOC 4 Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench NOTE If connecting to 100 CO cylinder insert regulator adapter between regulator and cylinder valve adapter is equipped with a plastic washer be sure it is seated for connection to the CO 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 Return to Section TOC Return to Master TOC 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 Alw
139. TOC POWER MIG 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o 515 gt 2 2 2 Return to Section Return to Master TOC F 33 F 33 TROUBLESHOOTING amp REPAIR POWER MIG 300 SCROLLING DASHES TEST continued TEST PROCEDURES For Machines with code 10952 10958 Machines with code 10562 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 9 PrESSP in 3 Release the select switch 3 Turn the right encoder knob until displays show CLrAll 4 Machine will reset itself 4 Toggle the select switch up and release 5 Machine will reset itself POWER MIG 300 LINCOLN 5 34 34 TROUBLESHOOTING amp REPAIR OSCILLOSCOPE WAVEFORMS MUST BE TAKEN IN MODE 201 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM Return to Section TOC Return to Master TOC o 2 5 2 3 Return to Master 20 0 V 2 0 MS DIV This is a typical DC output voltage waveform generated from a properly operating machine Note t
140. ULATING COMPOUND 1 524951 4 CPLD SOFTWARE 1 50 FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENTS DATABASE FOR COMPONENT SPECIFICATION 11559 R13 17789 2 R5 R4 R9 R3 R8 R6 C5 X C2 C3 C4 C5 C6C7 C8 525020 35 _ CAPACITOR SIVD CERAMIC O 1MF 50V 1096 X7R S0805 5 1 1 DIODE SMD DUAL 0 200A70V UFR 36 1 18248 10 ______ 2 7 RESISTOR SVD2670HNS AW 1206 96 TR R3 R4 R5 R6 R8 R9 525000 12125 15 5 METAL FILM 1 10W 12 1K 1 S0805 R10 R11 R12 R 13 NA 15 wa R12 R11 4 85 5 00 N B 12 21 2001A L 11559 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 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 LINCOLN amp ine LINCOLN machine POWER MIG 300 22 ELECTRICAL DIAGRAMS G 22
141. YMBOLS PER E1537 4 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED e JL ea ae LABELS T u UNLE olco bv 1 ISOLATION BARRIER SUPPLY VOLTAGE NET 5 POWER SUPPLY SOURCE POINT o 3 R52 28 oe 57 COMMON CONNECTION 100 T 82527 50V FILENAM G3789_1D 7777 FRAME CONNECTION gt THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN ELECTRIC Sis EARTHIGRDUND CONNECTION o 34 0 AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO z j 3 Meme EE INVERTER WELDERS mt HOLES SIZES 2056 3 Uv ON 2 PLACE DECIMALS 16 02 552 2000 CLEVELAND OHIO U S A SCHEMATIC DIGITAL CONTROL SINCE COMPONENTS OR CIRCUITRY PRINTED CIRCUIT BOARD MAY CHANGE PLACE DECIMALS 15 002 8 4 2000P 02 pul WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY ON ALL ANGLES IS 5 OF DEGREE SCALE NONE 5 NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE MATERIAL TOLERANCE 7 AGREE DR pate 08 02 2000 ck SUP S D G No G3789 100 gt WITH PUBLISHED STANDARDS 72 NUMBER oc c NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER MIG 300 ELECTRICAL DIAGRAMS ibid SCHEMATIC
142. a 400 1 0 280 1 0 425 1 0 400 1 0 42 3 16 550 1 0 340 1 0 670 1 0 500 1 0 z 1 4 600 1 0 400 1 0 700 1 0 550 0 9 5 Not Recommended Not Recommended Not Recommended Not Recommended below 200 WFS below 100 WFS below 200 WFS below 200 WFS POWER MIG 300 LINCOLN 5 13 POWER MODE The Power Mode process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop outs or burning through For Aluminum welding it provides excellent control and OPERATION B 13 Start by setting the wire feed speed based upon mate rial thickness and appropriate travel speed Then adjust the Volts Trim knob as follows For steel listen for the traditional frying egg sound of a good short arc MIG procedure to know the ability to maintain constant arc length This results you have the process set correctly in improved welding performance in two primary types of applications Return to Section TOC Return to Master TOC For aluminum simply adjust the Volts Trim knob Short Arc MIG at low procedure settings until the desired arc length is obtained Note the Volts Trim display is simply a relative number Aluminum MIG welding 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 respon
143. a 2 oz 3 822 215 ck 2 2 lt lt gt 25 100 l 15SPI n Bene 55 5 51 Res 10 hebs V d yee eset 516 QK2 p V 2210 015 BA 1 4 2 6581 Sor c 8 55 01 gu E S GSPI 7 Ge HC368A gu 36 C16 C10 C12 C13 C14 C15 200K 2 GSPI E DH ri J34 225 O17 017 017 017 Ol7T 3 7 2857 gt 5 5g 55 em am sov 500 Tsou sov sov soV sov 5 1 40 x wos ae o Ru EN X6 598 5 ale TH ZIEL 1 825 8 cls 88518 gt 65 o o 4 V lt La 09 GSPI a 72 m o wa m EY Ole 3p amp 95 gt zc a Q gt 2102 yE 2 eS 6 SS lt 86 2 d 03 EZ EISE gt t ss HCLL Ez 65 Go lt 2 Bs 9 9 TZIK D 13 py DATA Oui 85g uc 5 1465 5 17 5 EEEa 523 Fong o Ex 13 13 To 5 3 J34 RN ospr 0e BANK2 29598 iem cSt 4 R4 HCLL 127 23 8 TZIK lr 15 16 5 8 2 c gt AQ a D 25 52 RB 10 ai vl 10 ENABLE BANKSLT 58 2 8 TZIK 9 12 DATA IN A EN 11 n 6 7 DISP1 ez 5 7 6608 iso 12 STROBE CLOCK fe B 5 ele TZIK z 8 Rx cE 161 122 V Mci4489 0 Zip DIGIT2 25 B GSPI amp S 2
144. afety 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 5 DESCRIPTION This test will aid the technician in the removal and replacement of the Motor and Gear box 9 9 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 O10 O10 gt 23 e 5 5 ply o Return to Section Return to Master TOC POWER MIG 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ci iz 8 JE ply o Return to Section Return to Master TOC F 37 F 37 TROUBLESHOOTING amp REPAIR MOTOR amp GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT continued REMOVAL PROCEDURE 11 WARNING ELECTRIC SHOCK can kill 12 High voltage is present when input power is applied to the machine 13 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 4 Using the 5 16 in nutdriver remove the tool tray
145. age 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 Accessor 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 aluminu
146. ar moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side AR Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source LINCOLN 5 Return to Master Return to Master TOC Q 5 Return to Master SAFETY ELECTRIC SHOCK can 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 3 6 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
147. ays 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 CIS gt elg EIS 2 1 Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 8 1 TABLE OF CONTENTS o OPERATION SECTION 9 cenae EE Section B Definitions of Welding a 2 Product DescriptiOri 5 A eie RENS B 3 5 Controls and Settings arisk nsr B 3 B 4 Setting and c 5 Multi Process Panel FUunCtions uai A 6 AIC CODO 7 Wire Drive e 8 Changing Drive and Idle Roll Sets nnn nnne 9 9 Feeding Wire 1091 fue Exp Fato Spi cL RAE ua vas B 10 Pulse 11 2 Pulsed On PUSO eid eia iex 12 13 E d Q 2 2 E
148. ble solid state electronics POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC ojo o E e a gt 23 e 5 5 ply o ojo Return to Section TOC Return to Master TOC Return to Master TOC E 9 E 9 THEORY OF OPERATION FIGURE E 8 IGBT OPERATION GATE LLL LLL 2 27 BODY REGION lt DRAIN DRIFT REGION lt BUFFER LAYER INJECTING LAYER DRAIN 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 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 POSITIVE VOLTAGE dh APPLIED GATE BODY REGION lt DRAIN DRIFT REGION lt BUFFER LAYER lt INJECTING LAYER DRAIN B ACTIVE 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
149. broad may be faulty Replace CAUTION If 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 POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E 2 E olg iz 212 515 Return to Section Return to Master TOC F 8 F 8 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS No control of wire feed speed Other machine functions are nor mal POSSIBLE AREAS OF MISADJUSTMENT S WIRE FEEDING PROBLEMS 1 The wire feed speed encoder control may be dirty Rotate sev eral times and check if problem is resolved TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Perform the Wire Drive Motor and Tachometer Feedback Test The Wire Speed Encoder may be faulty If code is 10562 or below change Encoder PCB If code is above 10562 The Feeder Head Board may be faulty Replace There is no wire feed when gun trigger is pulled Normal open cir cuit voltage is present Check for wire jam at drive rolls the drive rolls are turning then check for a mechanical restric tion in the wire feed path
150. cal 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 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 POWER MIG 300 LINCOLN 5 4 INSTALLATION n FIGURE A 1 Triple Voltage Machine Input Connections INPUT SUPPLY CONNECTION DIAGRAM Return to Master TOC Return to Master TOC Q He 2 5 Return to Master TOC Disconnect input power before inspecting or servicing machine Do not operate with covers removed ELECTRIC SHOCK CAN KILL Only qualified persons should install use or service this equipment Do not touch electrically live parts Install and Ground machine National Electrical Code and local codes Use Grounding Stud or Lug inside Use CU wire only Consult Instruction Manual before installing or operating 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 fi
151. calibration is in progress The right hand display will scroll the following message Adj rEnc SorEAL vol 20V Adjust output control knob until the actual out put voltage reading on the test volt meter is 20 volts 5 volts POWER MIG 300 LINCOLN 5 F 53 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo e iz g 2 5 Return to Section Return to Master TOC F 54 F 54 TROUBLESHOOTING amp REPAIR VOLTAGE amp CURRENT CALIBRATION PROCEDURE continued 9 Wait for the machine s output to be automati 5 Release the mode select switch cally turned off and then back on 6 The left display will change to IcAL to indi Adjust the output control knob again if neces cate that current calibration is in progress sary to make the actual voltage output 20 volts 5 volts 1 7 The righthand 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 12 Repeat the above two steps if necessary ammeter is 250 amps 2A 13 Toggle the mode select switch up and release 9 Wait for the machine s output to be automati the switch to save the calibration setting cally turned off and the
152. 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 Return to Section TOC Return to Master TOC O10 O10 a gt 23 e 5 5 ply Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 5 51 51 TROUBLESHOOTING amp REPAIR FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT continued FIGURE F 16 FAN MOTOR ASSEMBLY REMOVAL Return to Section TOC Return to Master TOC o 2 5 2 3 Return to Master a Unplug the black lead from its in line connector 1 Attach the fan motor to the mounting bracket REMOVAL PROCEDURE 6 Remove the fan motor 1 Disconnect main input power to the machine a Loosen and remove the two nuts and lock wash ers from the motor mounting bracket using a 9 2 Remove the case side panels using a 3 8 in nut 11 32 in open end wrench driver 5 2 b When the motor is free from the mounting brack 8 E 3 Cutthe wire tie from around the fan motor leads et slide the motor from the POWER MIG unit 2 E 4 Disconnect fan motor leads REPLACEMENT PROCEDURE HE 2
153. contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo O10 E e a gt 3 e gt 5 5 ply o ojo Return to Section TOC Return to Master TOC 5 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No welding output but wire feeds normally when gun trigger is pulled Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel 2 The gun may be faulty Check for continuity 3 Check continuity through the work lead RECOMMENDED COURSE OF ACTION 1 Check for loose or broken con nections at the output terminals the choke and all heavy current carrying leads See the Machine Schematic Make sure that the transformer secondary leads are securely connected to the Output Rectifier assembly Check for OCV at output studs when trigger is pulled If OCV is present the gun may be faulty Replace Check for 57VAC at the input of output rectifier If reading is not correct Perform Transformer Tests If you mea sure approximately 57 VAC check for 80VDC at the o
154. crease the SPD value at the POWER MIG 300 to a value higher than the actual WFS 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 ACCESSORIES cS 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 PUSH PULL FEEDING CONNECTION ADAPTER 2154 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 kit is intended for use with the following Cobra Gold or Prince XL torches Air Cooled 15 5 1589 1 Water Cooled 15 5 1590 1 Air Cooled 25 8 1589 2 Water Cooled 25 8m 1590 2 Air Cooled 50 15 1589 3 Water Cooled 50 15 K1590 3 Air Cooled 15 5 Air Cooled 25 8m Air Cooled 50 15 1591 3 Water Cooled 50 15m K1592 3 CAUTION 1591 1 Water Cooled 15 5 1592 1 K1591 2 Water Cooled 25 8 1592 2 Remove all input power to the POWER MIG 300 before installing the Connection Adapter Kit 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 po
155. ctrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risqu
156. d B5 and resistor lead 2520 to the lower terminal marked 6 Install heavy lead B1 and resistor lead 2530 to the upper terminal marked iz g 2 5 o 7 Replace cable ties removed disassembly 8 Install the case side panels Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 5 43 43 TROUBLESHOOTING amp REPAIR CHOPPER BOARD ASSEMBLY REMOVAL AND REPLACEMENT WARNING Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 in Nutdriver 3 8 in Nut
157. ding Voltage Range 5 350 Amps 67 Volts 10 45 Volts RECOMMENDED INPUT WIRE AND FUSE SIZES SINGLE PHASE Input Voltage 230Amps 300Amps 75 C Copper Wire Frequency Hz 29 Volts 32 Volts AWG IEC or 10096 Duty Cycle 6096 Duty Cycle Sizes MM Breaker Size 208 60 6 16 mm 230 60 6 460 60 10 575 60 12 2 5 mm NOTE Use 10 AWG Grounding Wire 208V Input ONLY The duty Cycle Rating at 300 Amps is 40 PHYSICAL DIMENSIONS Height Width Depth Weight 31 79 in 18 88 in 38 78 in 255 Ibs 808 mm 480 mm 985 mm 116 kg WIRE SPEED RANGE Wire Speed 50 700 IPM 1 27 17 8 m minute POWER MIG 300 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC m 9 o 8 c 3 tc Return to Section TOC Return to Master TOC Q 5 Read entire installation section before starting installation SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves 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 DC manual stick weld
158. driver 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 E eS olg iz 8 e 5 5 ply Return to Section Return to Master TOC POWER MIG 300 LINCOLN 44 44 TROUBLESHOOTING 4 REPAIR CHOPPER BOARD ASSEMBLY REMOVAL AND REPLACEMENT continued FIGURE F 14 CHOPPER BOARD ASSEMBLY DETAILS Return to Section TOC Return to Master TOC o 2 5 2 3 Return to Master other side of chopper board REMOVAL PROCEDURE 6 Disconnect lead 607 from terminal B8 and lead 613 from terminal B7 at their in line connectors A WARNING 7 Using 7 16 in wrench remove heavy lead B8 to negative output terminal and B2 to choke from 3 9 ELECTRIC SHOCK kill the chopper board e 2 High voltage is present when input power is applied to Using 7 16 in wrench remove heavy leads B1 9 8 and B5 to output rectifier from the chopper board 212 9 Using the 5 16 in nutdriver remove the 4 screws E NOTE Cut cable ties as needed to improve access holding the fan baffle to the machine base This 5 215 will allow you to move the baffle back out of the See Figure F 14 for the following procedure wa
159. e enclosure panels of your machine E POWER MIG 300 os ELECTRICAL DIAGRAMS WIRING DIAGRAM POWER MIG 300 CODE 11097 AND 11098 ONLY 53 5232 CONNECTOR EE 4 _ DIGITAL POWER SUPPLY BOARD S 2 BOARD k 5 3 3 6 4 4718 RE gt 5 gt 56 FLEX CIRCUIT SHIELDED 7 CABLE CONTROL gt 2 RECTIFIER 20 Return to Section TOC Return to Master TOC P C BOARD CONNECTION DETAIL SHIELDED CABLE L1 SHOWN CHOKE STUD CONNECTED FOR 230 RECONNECT PANEL W Return to Master TOC MSP III BOARD X eA 5 SWITCH 9 503 ia i _ 3 gt 3417 amp 3411A 9 TO STUD 4 adis 7 GAS TRIGGER DUAL PROCEDURE Ss SOLENOID 79 36 gt WIRE DRIVE M MOTOR DISPLAY SPOOL GUN 834 137 BOARD PUSH PULL 7 1234 Return to Section TOC 20 53 Y 1 PANEL ENCODERS VOLTS TRIM WFS AVPS 3 2 1 32
160. e 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 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 WIRE REEL LOADING READI REELS SPOOLS OR COILS 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 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 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 B 9 OPERATION B 9 5 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 6 Position the Readi Reel so that it will rotate in a direc tion when feeding so as to be de reeled from top the of the coil 7 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 8 Lower the Readi Reel to depress the retaini
161. ection TOC Return to Master TOC CIS mie g 9 EIS 2 1 Return to Section TOC Return to Master TOC 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 CV Processes 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 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 When
162. ection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place POWER MIG 300 LINCOLN amp MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page i iv Installation ELE Section Section Section Section Theory of Operation icri se Ex rece Section E Troubleshooting and Repair Section F How to Use Troubleshooting Gulde iiie eite F 2 Troubleshooting 2 F 4 Test d DEARA aan F 14 Replacement Procedure pa aa lca ERE E CE F 36 Electrical Diagrams oe
163. ed 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 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC gt elg EIS 2 1 Return to Section TOC Return to Master TOC A 5 GUN AND CABLE INSTALLATION A Magnum 300 gun and 15Ft 4 6m cable 12Ft 3 7m for Codes 11000 and below provid ed with the POWER MIG 300 A Magnum cable liner for 035 045 0 9 1 2 mm electrode and contact tips for
164. er AC welder with reduced voltage control Do not operate with panels removed Disconnect input power before servicing FUMES AND GASES be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone and general area WELDING SPARKS can cause fire or explosion Keep flammable material away v 2 5 5 not weld on closed contain ers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion NM Observe all safety information through out this manual INSTALLATION dus ONLY QUALIFIED PERSONNEL SHOULD INSTALL USE OR SERVICE THIS EQUIP MENT UNCRATING THE POWER 300 Cut banding and lift off cardboard carton Cut banding holding the machine to the skid Remove foam and corrugated packing material Untape accessories from Gas Bottle Platform Unscrew the two wood screws at the Gas Bottle Platform holding the machine to the skid Roll the machine off the skid assembly LOCATION 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 INPUT POWER GROUNDING AND CONNECTION DIAGRAMS 1 Before starting the installation check with the lo
165. er form best when the droplet size is regulated by pinch to reduce the droplet size transferred with each short circuit event 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 7 596 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 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 Important to note here is that if a component of a pulsed waveform is increased then another must be decreased Adding pulsed frequency through
166. erating 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 Ifthe 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 fan as needed system is controlled by the Weld Control Board via solid state relay OVER CURRENT PROTECTION 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 relia
167. ermine 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Analog 3 8 Socket wrench and 6 extension 7 16 Nut driver olo E e olg iz 8 e 5 5 ply Return to Section Return to Master TOC POWER MIG 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 2 st olg iz 8 e 5 5 ply Return to Section Return to Master TOC F 17 F 17 TROUBLESHOOTING amp REPAIR CHOPPER BOARD TEST continued TEST PROCEDURE FROM TO EXPECTED 1 Disconnect the main AC input power to the LEAD LEAD VOLTAGE machine 437 1 99 431 4 99 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 J 99 Later machine do not have J 99 4 Make the following voltage test From the table RESISTANCE TEST below 1 Perform the Capacitor Discharge Procedure 5 Turn the machine off between each test 2 Remove input power to the machine a Carefully insert meter probes into the back of each
168. es 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 BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC Excellent appearance of the weld bead Improved cleaning action Reduced porosity Table shows WFS and 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 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 spray arc to a short arc which is not advisable when welding aluminum WELDING PROCEDURES FOR PULSE ON PULSE TABLE B 3 MATERIAL Aluminum 4043 Aluminum 4043 Aluminum 5356 Aluminum 5356 GAS 100 Ar 100 Ar 100 Ar 100 Ar WIRE E4043 E4043 E5356 E5356 WIRE SIZE 0 035 3 64 0 035 3 64 WELD MODE 98 99 101 102 14 ga 250 1 0 200 1 0 230 1 0 225 1 0 28 2 E 10g
169. es d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 du corps PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER done TRANSFORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de prot
170. f the equipment frame ATTENTION Static Sensitive 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 Devices Handle only at Static Safe Workstations Tools which come in contact with the PC board must be either conductive anti static or static dissipative 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 the PC board uses protective shorting jumpers don t remove them until installation is complete 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 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 NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original prob
171. g 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 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 Figure B 2 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 POWER MIG 300 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC CIS 2 2 EIS 2 1 Return to Section TOC Return to Master TOC BY OPERATION B 7 Arc Control See Table B 2 There are no specific unit values offered because the setting of this feature largely depends upon operator preference Arc Control has a different effect on the character of the arc depending upon the welding process applied In SMAW STICK mode arc control adjusts the arc force It can be set to the lower range for a soft
172. gic 6 connector for a foot amptrol or remotes and a 7 and non synergic CV GMAW GMAW P Pulse on pin connector to allow operation of a spool gun or a Pulse and Power Mode welding processes push pull gun for feeding aluminum wires NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo OJO E e a gt 23 e 5 5 ply o ajo Return to Section TOC Return to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 INPUT RECTIFIER CHOPPER ASSEMBLY AND FEEDBACK MAIN TRANSFORMER RECONNECT PANEL LINE SWITCH 40 FROM WELD VDC CONTROL BOARD FOOT AMPTROL OR REMOTE 6 PIN AMPHENOL SPOOL GUN OR PUSH PULL GUN 7 PIN AMPHENOL GAS SOLENOID WIRE DRIVE MOTOR OUTPUT RECTIFIER De 2256 DIODE CONTROL RECTIFIER 15 15 5 VDG IGBT BOARD SHIELDED FEEDER CHOPPER ASSEMBLY OUTPUT TERMINAL OUTPUT C CURRENT TRANSDUCER OUTPUT TERMINAL CURRENT FEEDBACK VOLTAGE FEEDBACK PWM SIGNALS DRIVE S WELD CONTROL BOARD CRM TEM TO FAN RELAY ENCODER BOARD Below code 10900 O SPOOL GUN PUSH PULL SWITCH Mechanical Encoders Above code 10900 INPUT VOLTAGE AND MAIN TRANS FORMER
173. h the flex hose and clamp compartment Return to Section TOC Return to Master TOC 6 Attach the tool tray 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 Return to Section TOC Return to Master TOC FIGURE F 11 FOR CODES BELOW 10952 ojo O10 E E a 23 e 5 5 ply ajo Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 5 39 FIGURE F 12 FOR CODES ABOVE 10958 POWER MIG 300 LINCOLN E TROUBLESHOOTING amp REPAIR MOTOR amp GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT continued DOL 49159 DOL 49159 901 Je1se N 0 uunjeH NOL Je1se N 0 uunjeH DOL uonoeg DOL uonoeg DOL uonoeg DOL uonoeg 40 40 TROUBLESHOOTING amp 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 man
174. hat 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 S SCOPE SETTINGS ele Volts D V 20V Div E Horizontal 5 2 5 ms Div COU TG DC ce Internal CODES 10562 AND BELOW CODES 10952 AND UP o o 1 Power Mig 300 in mode 201 Mode 201 is Power Mig 300 in mode 201 Mode 201 is a con stant current test mode stant current test mode 1 Toggle and hold the Mode Select switch in the up 1 Toggle and hold the Mode Select switch in the up position position 2 Turn on the Power Mig 300 2 Turn on the Power Mig 300 5 3 Rotate the right output knob while still holding the 3 Once the display reads Pres Spin release the 2 E Mode Select switch up until the display reads mode select switch Rotate the output knob until 912 ALL nodE the display reads ALL nodE yi 4 Release the Mode Select switch and toggle the 4 Toggle the Mode Select switch once and wait for Mode Set switch until the MSPIII panel reads 201 the machine to reset then toggle the MODE SET 5 Disengage the idler arm on the wire drive so switch until the MSPIII panel reads 201 Disengage 9 wire will feed the idler arm on the wire drive so no wire will feed
175. he Welding or Start wire feed speed Setting a Run In WFS lower than the welding WFS avoids stubbing problems when starting the arc e 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 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 For SMAW Stick welding setting a Hot Start helps to minimize stubbing the electrode For GTAW TIG welding setting a Cold Start minimizes burn through of thin materials when not using a manual amperage control 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 spreadin
176. high resis tance in one polarity and low resistance in the oppo site polarity See Figure F 7 Negative Lead i 17 If any of the diodes are leaky or shorted the output rectifier assembly should be replaced When the testis complete replace the negative out put previously removed Replace case side POWER MIG 300 LINCOLN 23 23 TROUBLESHOOTING amp REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST WARNING Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nutdriver Volt Ohmmeter O10 E 2 a gt 23 e 5 5 ply ajo Retur
177. ied 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 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 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o 5 5 PEN gt 5 e 5 5
178. ion Return to Master TOC F 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No control of arc voltage Wire feeding is normal Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S FUNCTION PROBLEMS 1 The arc voltage encoder may be dirty Rotate several times and check if problem is resolved RECOMMENDED COURSE OF ACTION 1 The arc voltage encoder may be faulty Codes 10562 have both Encoders on one board Codes above 10562 have single Encoders 2 machine has code 10562 or lower change Encoder Board If machine has Code above 10562 Perform Encoder Test 3 Perform the Chopper Board 4 The Control board may be faulty Replace There is no gas flow when gun trig ger is pulled Wire feeds and weld voltage is present 1 Check gas source and hoses for leaks or kinks 2 Check regulator on the tank for the pressure being set to high 1 Check for 6 5 VDC when trigger is pulled at feedhead Board Plug J 83 3 lead 833 and J 83 4 lead 834 See Wiring Diagram 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 83 3 amp 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
179. ithin 1 volt 8 The Power Mig 300 ammeter must match the test meter within 5 amps 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 NOTE Before attempting to calibrate the voltage or current setting of the Power Mig be sure to read the entire voltage or current 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 VOLTAGE CALIBRATION 1 Connect resistive load bank approximate ly 106 ohms and test voltmeter to the weld ing output terminals 2 Toggle and hold in the mode select switch in the up position 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 Release the mode select switch once 6 The left display will change to VcAL to indi cate that voltage calibration is in progress 7 The right hand display will scroll the following message Adj rEnc SorEAL vol 20V 8 Adjust output control knob until the actual out put voltage reading on the test volt me
180. l change from zero to15 volts to zero to 15 volts etc as you continue to turn the encoder POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E olg iz 8 e 5 5 ply Return to Section Return to Master TOC F 28 F 28 TROUBLESHOOTING amp REPAIR ENCODER PC BOARD TEST continued VOLT TRIM ENCODER 1 FROM LEAD LEAD EXPECTED VOLTAGE ACTION If you do not read 15VDC on the first reading of encoder 855 3243 15 VDC 1 or 2 then check lead connections If lead connec 5 85 3 82 tions check OK then Feeder Board may be faulty replace Feeder Board 8511 3243 0 OR 15 VDC As you turn the encoder 1 or 2 slowly you should see 11 85 3 82 your meter go from 0 to 15 0 to 15 as you turn the encoder If not check the lead connections If the lead 858 3243 0 OR 15 VDC connection check OK then change the encoder 8 85 3 82 WMF AMPS ENCODER 2 FROM LEAD LEAD EXPECTED VOLTAGE ACTION If you do not read 15VDC on the first reading of encoder 859 3243 15 VDC 1 2 then check lead connections If lead connec 9 85 3 82 tions check OK then Feeder Board may be faulty replace Feeder Board 857 3243 0 OR 15 VDC As you turn the encoder 1 or 2 slowly you should see 7 85 3 82 your meter go from 0 to 15 0 to 15 as you turn the encoder If not check the lead
181. l or background maintains the arc between pulses See Figure B 5 OPERATION B 11 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 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 2 gt lt x lt FREQUENCY gt SPRAY TRANSITION CURRENT POWER MIG 300 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC CIS gt elg 5 2 21 Return to Section TOC Return to Master TOC B 12 PULSE ON PULSE GMAW PP Pulse on Pulse is a Lincoln process specifically
182. lem does not reappear by substituting the original board then the PC board was notthe problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b 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 6 Always indicate that this procedure was followed when warranty reports are to be submitted 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 POWER MIG 300 LINCOLN 5 4 4 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e olg iz 212 515 Return to Section Return to Master TOC SYMPTOMS Major physical or electrical damage is evident MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Contact your local Lincoln Authorized Field Service Facility 1 Contact the Lincoln Electric Service Department at 1 800 833 9353 WELD Machine is dead no welding out put and no wire feed when gun trigger is pulled
183. linder supports wheel axles and mounting hardware ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES 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 2 ACCESSORIES C 2 English Wire Metric Wire Length Part No Size Size 10 3 0 12 3 6 m 15 4 5 035 045 MAGNUM GUN CONNECTION KIT Optional K466 6 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 K1692 2 SPOOL GUN PRINCE 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 CAUTION 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 1 Pulling the t
184. ly note placement of the fasteners bolt flat washer heavy lead terminal lock washer nut 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 POWER MIG 300 LINCOLN 5 42 42 TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 lea
185. m 4J3244 83321 ojo 2 iz 5 me um 3243 IN OFF POSITION ies ame ppm H LOCATED TO THE RIGHT LED7 LOCATED AT BOTTOM OF WIRE DRIVE ASSEMBLY BRIN FOOTANETROS P C BOARD COMPARTMENT ON CENTER PANEL RED 157 167 6 GREEN LOCATED ON DIVIDER PANEL IN THE WIRE DRIVE COMPARTMENT CONTROL BOARD LED LEGEND LEDI TO CONTROL P C BOARD POCATED NEC LED2 15V POWER TO CONTROL P C BOARD ld LEDS 45V FOR SPI CABLE FRONT SIDE LEDA 15 FOR SPI CABLE LEDS 45V POWER TO CONTROL P C BOARD LEDS 45V FOR 15232 CONNECTOR z LED7 A FATAL ERROR HAS OCCURED LEAD COLOR CODE COMPONENT VALUE UNITS RECTIFIER BRIDGE LEDS 45V FOR CAN COMVUNICATION B BLACK CAPACITOR MEDVOLTS USED ONLY FOR LED9 ANDLEDIO ERROR CODE LED9 BLINKS ONCE G GREEN EXTERNAL DIODE THENLEDIOBLINKS ERROR RESISTOR OHMS WATTS USED FOR MOTOR BRAKING LOCATEDINP C BOARD U BLUE CONNECTOR PIN NUMBERS COMPARTMENT W WHITE Y YELLOW 858 8511 857 PANEL ENCODERS SPOOL GUN PUSH PULL WFS AMPS VOLTS TRIM SWITCH 15VDC WHENIN THE SPOOL GUN POSITION OVDC WHENIN THE PUSH PULL POSITION 9 85 859 d 7 85 FOR CODE 10952 HIGHER EX 12PIN CONNECTOR LABELS 777 FRAME GROUND LL EARTHGROUND VIEWOF CONNECTOR ONPC BOARD MM 1566 8510
186. m wires a spool gun remotes and a foot amptrol B 3 OPERATION B 3 Other features 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 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 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 POWER MIG 300 LINCOLN Return to Section TOC Return to Master TOC Return to S
187. move 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 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o CIS elg EIS 2 1 Return to Section TOC Return to Master TOC D 3 MAINTENANCE piis CAUTION Excessive pressure at the start may cause the dirt to form a plug 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 LINER REMOVAL AND REPLACEMENT SEE FIGURE D 1 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
188. mp REPAIR CONTROL RECTIFIER TEST continued FIGURE F 5 15 30VAC NON X5 X6 CONTROL RECTIFIER gt bpo _Locaren ON TRANSFORMER BAFFLE __ 42 ng 6800 75 e TEST PROCEDURE 2 Carefully connect the meter probes to the exposed lead connections 1 Find the following leads at the control rectifier using figures F 5 and F 6 From Lead To Lead 3 Turn the machine ON to conduct the voltage test 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 POWER MIG 300 LINCOLN 5 21 21 TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC 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
189. n back on 14 The right display will display the message 10 Adjust the output control knob again if neces VcAL SAVEd Within 5 seconds hold the sary to make the actual output current read mode set switch in the up position until the ing on the test ammeter 250 amps 2A right display stops blinking I 11 Wait for the machine s output to be automati 15 The machine will reset to normal operation cally turned off and then back on after a few seconds 1 NA Repeat 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 13 Toggle the mode select switch up and release the calibration mode and use the previ the switch to save the calibration setting ous calibration settings 14 The right display will display the message CURRENT CALIBRATION ICAL SAVEd Within 5 seconds hold the mode set switch in the up position until the PROCEDURE right display stops blinking 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 jT the P Mi
190. n to Master TOC F 11 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual FAULT CODES DESCRIPTION DEFINITION F 11 TROUBLESHOOTING GUIDE CORRECTIVE ACTION WELDING PROBLEMS Glitch on the primary over current fault interrupt possibly caused by noise or a signal level Check the machine ground Check for cuts or marks on input cord SERVICE FACILITY CORRECTIVE ACTIO Check input cord for cuts or marks Check input cord connections at reconnect panel Main CPU problem The DSP has detected a prob lem with the CPU Check the machine ground Check for cuts or marks on input cord Check input cord for cuts or marks Check input cord connections at reconnect panel If still bad replace Control PCB 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 turn back on Run Scrolling dash Test If still bad replace Control 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 Motor over current aver age motor current exceeded 3 50 amps for more than 10 0 seconds Verify motor armature
191. n to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC 5 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK 9 can kill Have 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 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 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 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 PC board be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety usea 1 Meg ohm resistive cord connected to a grounded part o
192. n to Section TOC Return to Master TOC POWER MIG 300 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o c 5 B Return to Section TOC Return to Master TOC Q 2 8 24 24 TROUBLESHOOTING amp REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued FIGURE F 8 PLUG J83 AND J84 LOCATIONS ON FEEDER BOARD TOROD 1 MOTOR 831 lt 1 83 2 aemp 82 4 2083 PWM CONTROLLED assumer 5 es 6 5 VDC WHENGAS LOCATED ON 96 MEASURES 21 OHMS 12 VDC CAL 54 BY REMOVINGTHE WIRE MOTOR GEARBOX TACH DRIVE ASSEMBLY 2 6 MM R R 1 184 27 4 700 83 20 8 SECOND AVERAGE CURRENT macof Bayt CI ed 4 MEASUREBTOU pes LIMIT IS SOFTWARE SET 120 Hz 50 INMIN 1 6 kHz 700 IN MIN 84 J 00 184 83 JOOO00 COO 00000000 844 FOO 847 833838381 00000000 HH oot OO OO 832 841 ROO 831 TEST PROCEDURE 5 Connect the main power to the machine NOTE POLARITY MUST BE OBSERVED FOR 7 Make the following voltage tests Fr
193. ng spring and align the other inside cage wires with the grooves in the molded adapter 9 Slide cage all the way onto the adapter until the retaining spring pops up fully 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 FIGURE B 4 2 SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR READI REEL INSIDE CAGE WIRES RELEASE BAR TO MOUNT 10 to 44 Lb 4 5 20 kg SPOOLS 12 300 mm Diameter or 14Lb 6 Kg Innershield Coils For 13 14 Ib 6 Kg Innershield coils a K435 Coil Adapter must be 1 Open the Wire Drive Compartment Door 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 POWER MIG 300 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to
194. o 02 scale ___ COMPONENTS OR CIRCUITRY OF CONTROLS HAVING 01 16 2007 5 G 3997 160 2 COMMON CODE NUMBER DR 8 DATE CHK SUP S 0 G NO 5 Siz Ld rc NOTE This diagram is for reference only It may not be accurate for machines covered this manual LINCOLN 59 ELECTRIC POWER MIG 300 CN 1 tc ON 9 5 4 5 3199 Zd 3002 NOWWOO V 9 092 8550 LHS 1002 02 70 11926 94 51081502 40 HO SIN3NOdWO2 3NON 10 129 IHL MOHS LON AV VHOVIG 25 82d 83002N3 vn 7571 OIHO ONV T3 3 19 0508 V JO ALT 510 1 02 79 910 NOWWO2 ios 05 21919373 N IOONE T TE AUN 09908 C3INISG 45 26 45 9 NO AYLINOYID
195. oln 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 LINCOLN amp ine LINCOLN machine POWER MIG 300 6 16 ELECTRICAL DIAGRAMS G 16 SCHEMATIC FEEDER PC BOARD BOARD CODE 10562 11098 SHEET 1 ISOLATED ARCLINK SECTION 6 RESETQ Ua x39 78 054 1 187 5 80746 GND 8 287 DS 3 100 01W VPPOFF 1 5287 FREEZE 781 RESET Nn Co nf 5 0 amp 1 1181 E xn 287 BERR 287 AFETCH con PWRON lt lt SCANL Return to Section TOC Return to Master TOC 2 3 512K 16 FLASH 13 vpp 1 RESET 12 25 24 DATAIOI ADRI 73 ADR 22 DATA
196. oltage he welding arc is variable and sluggish Check the welding cable connec tions for loose or faulty connec tions Make sure the wire feed speed voltage and shielding gas are correct for the process being used l Check the OCV and Voltage Waverforms f wave forms are not correct P erform the Output Rectifier Assembl 2 Reload latest software from a Lincoln Electric sales representa tive 3 The Control Board may be faulty Replace he arc striking is poor Check the welding cable connec tions for loose or faulty connec tions Make sure the wire feed speed voltage and shielding gas are correct for the process being used Run in settings may need to be adjusted l Check the Output Voltage If waveforms not correct Perform the Output Rectifier Assembly Tests 2 Reload latest software from a Lincoln Electric sales representa tive 3 The Control board may be faulty Replace CAUTION If 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 POWER MIG 300 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o CiS PEN 9 gt 8 5 2 Return to Section Retur
197. oltage atH1 and H4 and at the bottom of the LINE SWITCH with the switch in the ON position f the voltage is incorrect check for loose or broken leads between the reconnect panel and the LINE SWITCH f the correct voltage is being applied to the main transformer primary winding proceed to the table below for the secondary winding output voltage tests Power to output X3 X4 Power to fan motor 115 VAC Power to control 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 LINCOLN 16 16 TROUBLESHOOTING amp 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 Return to Section TOC Return to Master TOC 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 det
198. om the table THESE TESTS below TEST FOR CORRECT WIRE DRIVE MOTOR 8 Carefully insert the meter probes into the back of ARMATURE VOLTAGE each Molex plug pin cavity to perform the test 1 Disconnect main input power to the machine 9 Tum 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 J 83 4 Locate leads 831 black and 832 white on plug 83 FROM LEAD TO LEAD EXPECTED VOLTAGE 831 832 2 5 27 VDC 1 83 2 83 varies depending on wire feed speed POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O10 5 5 0 218 5 Return to Section TOC Return to Master TOC F 25 F 25 TROUBLESHOOTING amp REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued TEST FOR SUPPLY VOLTAGE TO TACHOMETER AND FEEDBACK VOLTAGE FROM LEAD TO LEAD EXPECTED VOLTAGE 1 Locate the following leads on Plug J 84 Leads 841 1 84 and 844 4 84 2 Make the following voltage tests From the table below 10 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 FROM LEAD LEAD EXPECTED VOLTAGE 841 844 5 VDC 1 84 4 84
199. on Return to Master TOC Return to Section TOC Return to Master TOC O o olg iz 8 e 5 5 ply Return to Section Return to Master TOC F 31 TROUBLESHOOTING amp REPAIR CURRENT TRANSDUCER TEST continued TABLE F 2 CURRENT TRANSDUCER FEEDBACK VOLTAGE POWER 300 LINCOLN 5 31 32 32 TROUBLESHOOTING amp REPAIR POWER MIG 300 SCROLLING DASHES TEST WARNING Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED None E e olg iz 8 e 5 5 ply Return to Section Return to Master
200. other machine components are received and processed atthe Weld Control Board Software within the Weld Control Board processes the command and feedback information and sends the appropriate pulse width modulation P WM signals to the Chopper Assembly IGBT See Modulation in this section In this manner a digitally controlled high speed welding waveform is created olo OJO olg iz 8 e gt 5 5 ply o NOTE Unshaded areas of Block Logic Diagram subject of discussion Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC ojo o E 2 a gt 23 mlt 5 5 Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE E 7 WIRE DRIVE MOTOR AND FEEDBACK MAIN OUTPUT CHOPPER TRANSFORMER RECTIFIER ASSEMBLY ds OUTPUT CHOKE TERMINAL CUN CURRENT TRANSDUCER RECONNECT PANEL OUTPUT TERMINAL POWER avoc Es BOARD VOLTAGE FEEDBACK DIODE CONTROL BERIS RECTIFIER 15 15 5 VDC IGBT DRIVE WELD BOARD Gonnector 40 58 TO FAN RELAY CONTROL BOARD ARCLINK 5 VDC SHIELDED CABLE AND SPI COMMUNICATIONS DISPLAY BOARD FOOT AMPTROL OR REMOTE 6 PIN AMPHENOL
201. pressure arm to its origi nal position to apply pressure to the wire 4 Press gun trigger to feed the electrode wire through the gun 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 OPERATION B 10 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 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 AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures a Do not kink or pull cable aro
202. r 1 _ gt PS RESET 34 spisivovi0 25 x18 OSP_PS 21 po 05 5 FPGA INT 531 063 17084 B SPICS2 a 1 021 inp AH spisomiio 48 ay S3 POT CS 64 XCS20 208 17083 83 BMISO 25215 1 022 1 029 E E sur2 9 SA yrALL CLKIN SPICLK 10 H DISABLE 1 55 67 2 INT_1_3PH 1 023 Ip 3 51 Sock SHT 1 1 0667 1 082 SHT 1 24 b7 2 SPISTE D0 L2 5 sae SHT 1 FAN CONTROL___68 1 081 Bl MSELL SHT 3 1024 verpa ADCSOC I0PCO 63 THERMAL LED 6 po MSELO 33 116 DSP CLK ire s 2 ci SHT 1 1 069 1 080 SHT 3 SABE TS CLKOUT IOPC2 D 01 STT_ON 291 070 1 076 6 I FLOW STT SHT 3 DSP DI0 15 38 2 65 7 exp 50V SHT 1 MISCL 1217072 5 MISCO SHT 1 39 OFF BIO IOPC3 25128 SHT 3 TURN OFF_N 731 073 01414 SHT 1 32 TRST CAPL OEPL IOPCA SHT 1 05 0101 3 00 58 aoso 1 05 DSP MP 31 Mp 2 0 2 10 5 SHT 1 OSP OIL 10 py SeA 56 5 CAP3 IOPL6 SHT 1 Y MaA lip azpil2 DSP AUI 55 255 5 88 VREFLO SHT 1 PSWI0 7 m 1203 14 DSP AGI fal ME Mb lo 18 44 RESERVED xTAL2 57 DSP DIA 1904 15 DSP AUI Ts Ts Ts Ts 34 5 8 ls 45V 0 _015 1 05 5 116 OSP_AIS ed bid TMS320F 240 p DSP D 6 11 mI DSP A 6 54 S a 2 la zx 2 8 28 17096 1 0138 138 05 7 18 7108 OSP_AI7 00K EE S E E P
203. rigger for the built in feeder gun Magnum 300 e 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 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 3 Operation with POWER MIG 300 Install the spool gun per the installation instructions the POWER MIG 300 input power ON Make sure that the Gun Selector Switch is in the Standard Spool position 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 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o m 2 o 2 5 Return to Section Return to Master TOC Q 5 Non Synergic Weld Modes Mode 5 Voltage is adjustable at the power source The right control knob on the power source will adjust the voltage that is displayed in the meter directly above it The left Display WFS AMPS on
204. ripples are less distinct Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 o 2 5 Return to Section Return to Master TOC Q 5 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 GMAW PP mode arc control adjusts the modulation fre 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 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 Crater The crater is the end of the weld which normally
205. rnator 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 POWER MIG 300 LINCOLN 5 Section F 1 Section F 1 TABLE OF CONTENTS e TROUBLESHOOTING amp REPAIR SECTION n Troubleshooting amp Repair Section sss emen Section F 8 How to Use Troubleshooting 2 0 F 2 PC Board Troubleshooting Procedures 3 4 11 2 Chopper Board Capacitor Discharge Procedure F 12 Main TRANS TONMEN c E an eo da 14 Chopper Board nne nnne nennen nennen F
206. rom the machine Perform the Chopper Board Capacitor Discharge Remove the right side panel using a 3 8 in nutdriv er as viewed from the front of machine Using the 1 2 in wrenches remove heavy lead B1 and small resistor lead 2530 from the output rectifi er lower terminal marked negative reassembly note placement of the fasteners bolt flat washer heavy lead small lead terminal flat washer lock washer nut Using the 1 2 in wrenches remove heavy lead B5 and small resistor lead 2520 from the output rectifi er terminal marked positive 4 For reassembly note placement of the fasteners bolt flat washer heavy lead small lead terminal flat washer lock washer nut 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 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 reassemb
207. rs ELECTRIC AND MAGNETIC FIELDS 5 be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to some cases it may be necessary to remove safety minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working ne
208. rs 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 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 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 Also see item 1 b Return to Master Return to Master TOC Q E Return to Master SAFETY WELDING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent 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 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
209. s constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 749 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 h To avoid scalding do not remove the radiator pressure cap when the engine is 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoo
210. se 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 4 In the Power Mode two variables need to be set Wire Feed Speed o nS 5 2 5 Return to Master TOC 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 COz shield gas olo e For Stainless select a Helium blend Tri Mix 55 59 For Aluminum use 100 a gt 0919 RECOMMENDED WELDING PROCEDURES FOR POWER MODE TABLE B 4 3 3 MATERIAL _ Aluminum 4043 Aluminum 5356 Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Mild Steel Stainless Steel Stainless Steel ply 1 WIRE E4043 E5356 L56 L56 L56 L56 L56 L56 E308L E308L WIRE SIZE 0 035 0 035 0 025 0 025 0 030 0 030 0 035 0 035 0 030 0 035 GAS 100 Ar 100 Ar 100 75 25 100 75 25 100 CO 75 25 gt Tri mix Tri mix 22 Not Recommended 100 0 8 Not Recommended 90 1 0 2 o E 20 ga 120 1 0 120 1 0 100 0 7 100 1 0 80 1 5 50 0 5
211. sol gt _ BANK BANK DATAJN cock SCHEMATIC DISPLAY PC BOARD CODE 10562 11098 DOL J91S N 20 uonoeg HBUTTON BOARD DISPLAY VAS 0 O VIA 4 THE LOCATIONS OF VIA 1 THRU VIA 5 ARE SILKSCREENED ON THE BOARD CONNECT A NORMALLY OPEN PUSI REMOVE R22 AND R23 AS FOLLOWS CONVERT TO TEST FIXTURE CONNECT A SPDT SWITCH AS FOLLOWS 70 POSITION TO TESTS ALL OTHER CHIP SELECT BOARDS POSITION B TO TESTS CS7 DISPLAY BOARDS 901 49 9 0 DOL uonoes DOL O1 DOL uonoes 0 uinjoeH LEFT DISPLAY BLOCK x0000010 BOARD 1D SS C53 CS2 51 4489DW Vss 50 MCi44890W 55 This diagram is for reference only It may not be accurate machines covered by this manual NOTE L 11108 OOL 49 9 0 DOL uonoeg POWER MIG 300 LINCOLN E 23 ELECTRICAL DIAGRAMS BOARD ASSEMBLY DISPLAY PC BOARD CODE 10562 11098 292 ENGINEERING CONTROLLED CHANGE DETAIL LEDS 6 amp 7 REVISED PART NUMBER DESCRIPTION REVISED IDENTIFICATION CODE AND SCHEMATIC REF NUMBER MANUFACTURER Yes ITEM REFERENCE DESIGNATORS QTY PART NUMBER DESCRIPTION L11757 E P C BOARD BLANK 115176 2 LED SPACER 0 140 HIGH 01 OZ E3539 ELECTRICAL INSULATING COMPOUND 424242222 FOR
212. tand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot S 9 ing assistance before you proceed Call 1 800 833 9353 WELD Fle 55 Ole gt DESCRIPTION 2 This test will help determine if the encoders are functioning properly for machines above code EIS 10562 only MATERIALS NEEDED Volt Ohmmeter analog recommended 5 16 Nut driver E olg iz 8 e 5 5 ply Return to Section Return to Master TOC POWER MIG 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o 515 gt 218 2 1 Return to Section Return to Master TOC F 27 F 27 TROUBLESHOOTING amp REPAIR ENCODER PC BOARD TEST continued FIGURE F 9 FEEDHEAD P C BOARD TEST PROCEDURE 1 Disconnect the main AC input power to the machine Locate the following leads on Plug J85 and J 86 located on the feedhead P C Board See Figure F 9 Connect main input power to the machine Make the following voltage tests From the tables on following page Turn the machine OFF between each test Carefully insert the meter probes into the back of each Molex plug pin cavity As you turn the encoder slowly the voltage wil
213. ter is 20 volts 5 volts POWER MIG 300 LINCOLN 5 F 55 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E gt gle e 5 5 ply ajo Return to Section TOC Return to Master TOC F 56 VOLTAGE amp CURRENT CALIBRATION PROCEDURE continued 10 1 I 12 13 14 15 TROUBLESHOOTING amp REPAIR Wait for the machine s output to be automati cally turned off and then back on Adjust the output control knob again if neces sary to make the actual voltage output 20 volts 5 volts Wait for the machine s output to be automati cally turned off and then back on Repeat the above two steps if necessary Toggle the mode select switch up and release the switch to save the calibration setting The right display will display the message SAVEd Within 5 seconds hold the mode set switch in the up position until the right display stops blinking The machine will reset to normal operation after a few seconds 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 CURRENT CALIBRATION PROCEDURE 1 Connect resistive load bank of approx 106 ohms and test ammeter to the welding output terminals Toggle and hold the mode select button
214. 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 SHIELDING GAS For Gas Metal Arc Welding Processes Customer must provide cylinder of appropriate type shielding gas for the process being used A gas flow regulator for CO or Argon blend gas and an inlet gas hose are factory provided with the POWER MIG 300 WARNING CYLINDER may explode if damaged 5 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 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 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 FEEDR END CABLE HANDLE INSULATION TUBE BRASS CABLE CONNECTOR 1 MOLDED GAS PLUG SET SCREW LINER ASSEMBLY LINER BUSHING TO BE SEATED TIGHT AGIANST BRASS CABLE CONNECTOR CLAMPING SCREW GUN HANDLE 5 GUN TUBE m 9 16 14 3mm SET sche 8 LINER TRIM et LENGTH GAS DIFFUSER NOZZLE INSULATION GAS NOZZLE POWER MIG 300 LINCOLN 5 A 6 INS
215. the previ ous calibration settings POWER MIG 300 LINCOLN 5 57 57 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine If itis rejected under test for any reason that requires you to remove any part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components TEST MODE 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 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC WIRE SPEED RANGE 50 700 IPM 1 27 17 8 m minute OUTPUT AMPS VOLTS 200A 27 30 E olg iz 8 e 5 5 ply Return to Section Return to Master TOC POWER MIG 300 LINCOLN 5 G1 ELECTRICAL DIAGRAMS 6 1 S TABLE OF CONTENTS n ELECTRICAL DIAGRAMS SECTION 3 EEECTRICAL DIAGRAMS a rmn e rc ees erac E PR RUE RU d GC e REC SECTION G 9 WIRING DIAGRAM CODE 10562 3852 G 2 E WIRING DIAGRAM CODE 10952 4068 G 3 5 WIRING DIAGRAM CODE 10958 AND 11000 64305 G 4 WIRING DIAGRAM CODE 11097 AND 11098 64511 G 5 ENTIRE MACHINE SCHEMATIC CODE 10958 and 11000 64315
216. they fail 6 h Also see item 1 c vai CYLINDER may explode if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in
217. ual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 E a 23 e 5 5 ply ajo Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC o 5 41 41 TROUBLESHOOTING amp REPAIR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continued FIGURE F 13 WARNING ELECTRIC SHOCK can kill High voltage is present when input power is applied to the machine NOTE Cut cable ties as needed to improve access See Figure F 13 for the following procedure l 2 Disconnect main input power f
218. und sharp corners b Keep the gun cable as straight as possible when welding or loading electrode through cable 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 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 h Use proper drive rolls and wire drive idle roll pres sure for wire size and type being used POWER MIG 300 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC X 8 EIS 2 1 Return to Section TOC Return to Master TOC B 11 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 leve
219. up 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 MAXIMUM 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 POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC o 2 5 2 Return to Section Return to Master TOC 5 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 SINGLE PHASE DC RECTIFIER SOLID STATE INDUCTOR INPUT POWER AND FILTER SWITCH AND DIODE CURRENT WITH SWITCH CLOSED In this system the engine drives a three phase alte
220. utput of the output rectifier If reading is not correct perform the Output Rectifier Assembly Tests 80VDC 15 there Perform Chopper Board Test Check for 15VDC input to the Control Board at leads 12J 4 412 to 10 4 410 15VDC at leads 11J 4 411 to 10J4 410 5VDC atleads 8J 4 408 to 10 4 410 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 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 POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC E 2 st olg iz 212 515 Return to Section Return to Master TOC F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Wire feeds but welding output is low causing wire to stub Welds are cold Machine cannot obtain full rated output of 300 amps at 32 volts POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make sure that the proper wire and procedures are being used Check gun and work cable for loose or faulty connections TROUBLESHO
221. wer source MAKING A WELD WITH THE PRINCE XL OR COBRA GOLD TORCH INSTALLED 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 Trim at the POWER MIG 300 using the right control knob located on the upper case front panel The Wire Feed Speed WFS 15 set using the control knob on the Torch The left control knob on the POWER MIG 300 is inactive The actual WFS being set 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 LINCOLN 5 C 4 NOTES POWER MIG 300 LINCOLN 5 901 J81Se N 01 901 J81Se N 01 901 J81Se N 01 901 0 DOL uonoeg uinjeg DOL uonoeg DOL uonoeg DOL uonoeg Return to Master Return to Master TOC Q 2 2 E Return to Master TOC D 1 D 1 TABLE OF CONTENTS MAINTENANCE EDDIE I Section Safety Precautions amp General
222. y 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 WELD MODE ELECTRODE 025 030 035 045 3 64 STEEL PREFLOW POSTFLOW Shes RUN IN 2029 94 1 21 pa cumann wos 30 95 W ARC CONTROL STAINLESS SAE wa 32 42 BUR
223. y to access the right rear nut on the chopper assembly bracket 1 Disconnect main input power from the machine 10 Using the 3 8 in wrench nutdriver remove the 4 2 Perform the Chopper Board Capacitor Discharge nuts holding the chopper assembly brackets to the machine base 3 Remove the case side panels using a 3 8 in nut 11 Carefully remove the chopper assembly from the driver machine 4 Label and disconnect thermostat leads 503 and 15 Using 7 16 in wrench remove the 2 support 503A brackets from the chopper board assembly gs Unplug J 99 from the chopper board Return to Section TOC Return to Master TOC POWER MIG 300 LINCOLN 5 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC O o 515 gt 2 2 2 Return to Section Return to Master TOC me TROUBLESHOOTING amp 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 1 and B5 4 Install heavy leads B6 and B2 5 Connect lead 607 B8 and lead 613 87 at their in line connectors 6 Connect plug J 99 7 Connect thermostat leads 503 and 503A 8 Install the case side panels
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Lincoln Electric SVM160-B User's Manual

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