Lincoln Electric IM555 User Manual

MIG PULSER

RETURN TO MAIN MENU

IM555

March, 1999

For use with machines having Code Numbers:

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
thoughtful 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.

10213

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

For Diesel Engines: Diesel engine exhaust and
some of its constituents are known to the State
of California to cause cancer, birth defects, and
other reproductive harm.

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 & Cutting - ANSI Standard Z49.1” 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 Gasoline Engines: The engine exhaust from
this product contains chemicals known to the
State of California to cause cancer, birth defects,
or other reproductive harm.

i

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing 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.

____________________________________________________

1.d. Keep all equipment safety guards, coversand devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

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 near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler
by pushing on the throttle control rods while
the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may 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

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

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.

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.

___________________________________________________

1.g. 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.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

ii

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.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

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.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

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.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

vapors

to

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

WELDING SPARKS can
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.

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.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. 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.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference.This information can be found
on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.

vv

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

TABLE OF CONTENTS

Page

SAFETY .......................................................................................................................................i-iv

INSTALLATION................................................................................................................Section A

TECHNICAL SPECIFICATIONS...........................................................................................A.1

SAFETY PRECAUTIONS.....................................................................................................A.2

LOCATION............................................................................................................................A.2

MOUNTING BRACKETS......................................................................................................A.2

HIGH FREQUENCY INTERFERENCE PROTECTION .......................................................A.2

ELECTRICAL INPUT CONNECTIONS................................................................................A.2

MACHINE GROUNDING...............................................................................................A.2

SUPPLY CONNECTIONS .............................................................................................A.2

CONNECTION TO A V300 ...........................................................................................A-2

CONTROL CABLE CONNECTION...............................................................................A.2

OUTPUT CABLES FOR PULSE WELDING ........................................................................A.3

USE WITH THE LN-9 GMA..................................................................................................A-3

CONNECTING A SPOOL GUN ...........................................................................................A.3

OPERATION.....................................................................................................................Section B

SAFETY PRECAUTIONS.....................................................................................................B.1

GENERAL DESCRIPTION...................................................................................................B.1

RECOMMENDED PROCESSES AND EQUIPMENT...................................................B.1

OPERATIONAL FEATURES AND CONTROLS............................................................B.1

DESIGN FEATURES AND ADVANTAGES....................................................................B.2

WELDING CAPABILITY .......................................................................................................B.2

LIMITATIONS ........................................................................................................................B.2

V300 SETTINGS ..................................................................................................................B.3

MIG PULSER CONTROLS AND SETTINGS.......................................................................B.3

OPERATION GUIDELINES ..................................................................................................B.3

PULSE WELDING PROCEDURE GUIDELINES .................................................................B.4

vivi

MAINTENANCE...............................................................................................................Section C

TROUBLESHOOTING.....................................................................................................Section D

DIAGRAMS ......................................................................................................................Section E

WIRING DIAGRAM ..............................................................................................................E.1

PARTS MANUAL ........................................................................................................P-273 Series

MIG PULSER

JAN98

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - MIG PULSER

INPUT

Model Description Volts Amps Frequency

K954-1 MIG Pulser 42 VAC 1 A 50/60Hz

OUTPUT

Output Frequency Peak Current Background Current Pulse Width
Range Settings Settings

20 to 300 Hz 250, 325 or 400 A 40 or 80 A 2 mS

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

2.5 in. 5.0 in. 7.0 in. 3 lbs (1.4 kg)
(without cables)

64(mm) 127(mm) 178(mm)

OPTIONS/ACCESSORIES

A-1

(K955-25) 25 ft. (7.5m) Control Cable Extension

EXISTING CASE TOP SCREWS

“HOOK” BRACKET

ENCLOSED RUBBER
BUMBER AND SCREW

INVERTEC V300

EXISTING CASE TOP SCREWS

UNIVERSAL BRACKET

MOUNTING HOLES TO
SECURE TO GENERIC
SURFACE

Figure A.1a - ”Hook” Bracket Installation for

mounting to a V300 Power
Source.

MIG PULSER

Figure A.1b - Universal Mounting Bracket

Installation for mounting to a
generic surface.

A-2

INSTALLATION

A-2

Read this entire installation section before you
start installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Only qualified personnel should per­form this installation.

•Turn the input power OFF at the dis­connect switch or fuse box before work­ing on this equipment.

•Do not touch electrically hot parts.

•Always connect the V300 grounding
terminal (located on the bottom of the
input connection box) to a good electri­cal earth ground.

------------------------------------------------------------------------

Only qualified personnel should install, use or service
this equipment

LOCATION

HIGH FREQUENCY INTERFERENCE
PROTECTION

A V300 with a MIG Pulser may not be suitable for use
near a high frequency arc starter (such as is found in
a TIG welding power source or a plasma cutter). The
V300 should be located at least 15 feet (5 meters) from
the high frequency source. There should be at least
25 feet (7.5 meters) or greater separation between the
ground connections and welding or cutting arcs of the
V300 and the high frequency source.

ELECTRICAL INPUT CONNECTIONS

MACHINE GROUNDING

The MIG Pulser is grounded to the V300 by the ground
lead carried inside the Control Cable. Ground the V300
according to all local and national electrical codes.
Also refer to the V300 operator’s manual for any other
grounding considerations.

SUPPLY CONNECTIONS

The MIG Pulser receives its input power from the V300
through the Control Cable.

The MIG Pulser can be used in the same locations and
environments as the V300. It is rated for use in damp,
dirty environments.

MOUNTING BRACKETS

Locate the two mounting brackets and rubber bumper
with screw that are supplied with the MIG Pulser in the
loose parts bag. To prevent accidentally dropping the
unit, always secure the MIG Pulser to a stable surface
with one of the brackets.

The first bracket is designed to “hook” onto the front
handle of the V300, allowing the MIG Pulser to be
located next to the V300 Control Panel. Attach this
bracket as shown in figure A.1a by using the two
screws from the top of the MIG Pulser. To prevent the
MIG Pulser from scratching the paint off the V300, affix
the rubber bumper to the bottom corner of the MIG
Pulser case with the longer provided screw.

The second bracket is a universal bracket that is
designed to allow the MIG Pulser to be fastened to any
secure surface. Attach the bracket to the desired sur­face. Then attach the MIG Pulser to the universal
bracket using the two screws from the top of the MIG
Pulser as shown in figure A.1b.

CONNECTION TO A V300

WARNING

Turn the Power switch on the V300 “OFF” before con­necting or disconnecting input power lines, output
cables or control cables.

------------------------------------------------------------------------

CONTROL CABLE CONNECTION

The MIG Pulser is supplied with a “wye” adapter for
making connections to the V300. The 14-pin plug
should be inserted into the V300 Wire Feeder recepta­cle, the 14-pin socket is for the wire feeder Control
Cable, and the 6-pin socket connects directly to the
MIG Pulser (Refer to figure A.2). If a DC TIG Starter is
attached and connected to the V300, the 14 pin Pulser
plug can be connected to the lower 14 pin socket on
the DC TIG STARTER, which is labeled “connect to
WIRE FEEDER”. Switch to “control at wire feeder” to
transfer control to the MIG PULSER.

The MIG PULSER cannot

be used for TIG welding.

MIG PULSER

JAN97

A-3

INSTALLATION

A-3

If the optional 25 foot Control Cable Extension is used,
it should be plugged into the 6-pin receptacle of the
wye adapter and then into the MIG Pulser. Only one
Control Cable Extension should be used; do not series
multiple extensions together. Using 50 foot or longer
control cables will cause the signals traveling between
the V300 and the MIG Pulser to degrade, leading to
poor welding performance.

NOTE: The voltage meter on the wire feeder will not
display voltage due to the lack of a 21 lead in the feed­er connection.

OUTPUT CABLES FOR PULSE
WELDING

Pulse welding generates high peak currents, which in
turn cause large voltage drops in welding cables. It is
essential that large cables (2/0 minimum) are used and
that all connections are clean and tight.

Because of voltage drops, the total length of the weld­ing leads (work lead length plus electrode lead length)
should not exceed 50 feet. If longer cables are used,
the maximum achievable output voltage will be
reduced.

NOTE: Do not coil the output cables around any
metal object.

USE WITH THE LN-9 GMA

Using the MIG PULSER with a LN9-GMA requires
installation of the voltage board bypass jumper. Other
adapters as called for in the V300 manual are not
needed for this usage, but can be left in if already pre­sent.

Problems with the trigger interlock may be experienced
when using the MIG PULSER with an LN-9 GMA
which has a L7265-2 Power PC Board. If needed,
replace with the latest Power PC Board available.

CONNECTING A SPOOL GUN

Refer to Figure A.3 for information about connecting a
spool gun in conjunction with the MIG PULSER.

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Figure A.2 Control Cable Connection.

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






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

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Figure A.3 Spool Gun Connection Diagram.

MIG PULSER

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


JAN97

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read entire section before operating this unit.
Additionally, read the V300 operator’s manual before
operating this unit.

WARNING

ELECTRIC SHOCK
can kill.

•Do not touch electrically live parts such
as output terminals or internal wiring.

•Insulate yourself from the work and
ground.

•Always wear dry insulating gloves.

------------------------------------------------------------------------

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 containers that have
held combustibles.

------------------------------------------------------------------------

ARC RAYS
can burn.

GENERAL DESCRIPTION

The MIG Pulser is a hand-held “pendant” type GMAW
Pulsing option for the V300 Pro and V300-I power
sources. It is a simple, easy-to-use unit, with a mini­mum of controls. It supports the GMAW-P (pulse MIG)
process on mild steel, stainless steel, and aluminum.
The MIG Pulser is supplied with a cable and brackets
for connection and mounting to a V300. An optional
control cable extension is also available which allows
the MIG Pulser to be placed up to 25 feet from the
V300.

RECOMMENDED PROCESSES AND
EQUIPMENT

The MIG Pulser/V300 combination can run the follow­ing processes:

GMAW-P

.035 steel, 100 - 700 IPM (90/10 Ar/CO
.045 steel, 75 - 400 IPM (90/10 Ar/CO2)
.035 stainless steel, 100 - 700 IPM (98/2 Ar/O
.045 stainless steel, 75 - 350 IPM (98/2 Ar/O2)
3/64 5356 Aluminum, 150 - 600 IPM (Ar)

The MIG Pulser/V300 combination can be used with all
wire feeders recommended for the V300 (LN-25, LN-7
family). It will also work with the Magnum Spoolgun
with limitations. No other options or accessories are
required or supported. Note: Using the MIG PULSER
with a LN9-GMA requires installation of the voltage
board bypass jumper on the LN9.

OPERATIONAL FEATURES AND
CONTROLS

)

2

)

2

•Wear eye, ear and body protection.

------------------------------------------------------------------------

Observe additional Safety Guidelines detailed in the
beginning of this manual.

MIG PULSER

The MIG Pulser has the following controls as standard:
Arc Length (continuously variable), Peak Current
(choice of Low, Medium and High), and Background
Current (choice of Normal and High).

B-2

OPERATION

B-2

DESIGN FEATURES AND ADVANTAGES

•Simple controls make this unit easy to set up and
adjust.

•The control algorithm is adaptive — it responds to
changes in stick-out and gun angle while maintaining
a stable arc.

•Designed to the IEC-974-1 standard.

•Attractive, rugged case includes carrying handle and
rubber feet.

•Unit is supplied with one bracket for mounting to the
V300, and one “universal” bracket for mounting to ver­tical or horizontal surfaces.

WELDING CAPABILITY

The V300 must be derated when used for GMAW-P
with the MIG Pulser. High peak currents required by
the pulse process increase the power source heating,
thus reducing the rated output. The V300 Pro and
V300-I (with three phase input) are presently rated 300
amps at 60% duty cycle. When pulsing, the ratings of
both models must be reduced to 250 amps at 60%.
The single phase rating of the V300 PRO must be
reduced from 250 amps/60% to 200 amps/60% when
pulsing. The single phase rating of the V300-I must be
reduced from 200 amps/60% to 150 amps/60% when
pulsing. Refer to Table B.1.

LIMITATIONS

The V300/MIG Pulser combination cannot be used
with long work and electrode leads. The total length of
the welding leads (work lead length plus electrode lead
length) should not exceed 50 feet. [If longer cables
are used, refer to the

Welding

tions.]

The Magnum Spoolgun/MIG Pulser combination will
not run low wire feed speed, fine wire aluminum pro­cedures well. These wires are best run in a spray
mode; GMAW-P offers few advantages in those areas.

The voltage meter on the wire feeder will not display
voltage due to the lack of a 21 lead in the feeder con­nection.

The V300 with a MIG Pulser may not be suitable for
use near a high frequency arc starter (such as is found
in a TIG welding power source or a plasma cutter).
Refer to
section in the Installation section of this manual.

Problems with the trigger interlock may be experienced
when using the MIG PULSER with an LN9-GMA that
has a L7265-2 power board.

section in the Installation chapter for limita-

High Frequency Interference Protection

Output Cables for Pulse

TABLE B.1 V300 OUTPUT DERATING

V300 PRO Standard V300 PRO Rating V300 PRO Rating when Using

Input Power (without MIG Pulser) MIG Pulser

3 Phase, 60 Hz 300 Amps / 60 % Duty Cycle 250 Amps / 60 % Duty Cycle
1 Phase, 60 Hz 250 Amps / 60% Duty Cycle 200 Amps / 60% Duty Cycle

V300-I Standard V300-I Rating V300-I Rating when Using

Input Power (without MIG Pulser) MIG Pulser

3 Phase, 50 Hz 300 Amps / 60 % Duty Cycle 250 Amps / 60 % Duty Cycle
1 Phase, 50 Hz 200 Amps / 60% Duty Cycle 150 Amps / 60% Duty Cycle

JAN97

MIG PULSER

B-3

OPERATION

B-3

V300 SETTINGS

Read and understand the V300 Instruction Manual
before attempting to use the V300/MIG Pulser system.
Also refer to figure A.2 in the Installation chapter.

The V300 must be set to the TIG Mode when using the
MIG Pulser. This is because pulse welding is a current
controlled process, not a constant voltage process like
straight GMAW. By using the GTAW position, the
V300 is placed in a current control mode, and the Arc
Force/Inductance control is made inactive.

The Wire Feeder Voltmeter Switch on the back of the
V300 must be set to the “-” position (normally called the
“electrode negative” position) although the MIG Pulser
is used for electrode positive welding. The setting
allows the MIG Pulser to sense arc voltage.

The V300 Local/Remote Switch must be set to Remote
Control. This allows the MIG Pulser to control the V300
output. The Output Control on the V300 is not func­tional in the Remote Control mode.

Other V300 settings should be made according to the
installation conditions and the wire feeders used.

OPERATION GUIDELINES

The suggested steps for initially establishing a welding
procedure are as follows:

1. Set the Peak Current to Low, Background Current to
Normal, and Arc Length to minimum.

2. Set the desired wire feed speed on the feeder

3. Pull the gun trigger to establish an arc. Increase the
Arc Length setting until a stable arc is present. (If
the arc will not start with the Arc Length set to min­imum, raise the Arc Length until a good start
occurs.)

4. Once a stable arc is established, the Peak Current
level can be increased, resulting in a broader, soft­er arc. This might be useful for out of position work,
or for low travel speeds. Conversely, for faster trav­el speeds, lower Peak Current settings are recom­mended.

5. The Background Current affects the overall heat
input to the weld. It also can affect arc stability. Too
low of a Background Current can lead to a “pop­ping” arc.

MIG PULSER CONTROLS AND
SETTINGS

The MIG Pulser has three adjustments, consisting of
two switches (Peak Current and Background Current)
and one knob (Arc Length). See figure B.1.

LOW MED. HIGH

PEAK AMPS

ARC LENGTH

Figure B.1 MIG PULSER Controls

NORMAL HIGH

BACKGROUND
AMPS

Adjusting the Peak Current, Background Current or
Arc Length will lead to changes that can be both seen
and heard in the arc. It is best to experiment with var­ious settings to familiarize yourself with their effects.

If the wire feed speed is changed at the wire feeder, it
is typical to need to raise the Arc length setting also. If
the wire feed speed is increased a great deal, it may be
necessary to increase the Peak Current setting as well.

Changes in wire size require similar procedural
changes. Larger wire sizes require higher Arc Length
settings, and possibly higher Peak Currents.

Note that a sound weld with good operator appeal can
be achieved with more than one combination of set­tings. For instance, raising the Peak Current one posi­tion typically raises the arc length, causing a definite
change in the sound of the weld.

The MIG Pulser is based on “adaptive” principles. In
an adaptive pulser, many variables can affect the arc
length: Stick-out, gun position, weld position, gas mix­ture, electrode composition, electrode surface condi­tion, the switch settings and the Arc Length control. All
of these conditions feed back into the circuitry allowing
the MIG Pulser to adapt the arc length to the welding
conditions.

MIG PULSER

B-4

OPERATION

B-4

PULSE WELDING PROCEDURE
GUIDELINES

Tables B.2 and B.3 list initial settings guidelines for
pulse welding with the MIG PULSER for Stainless
Steel and Mild Steel. These settings are intended as
suggestions only. The serviceability of a product or
structure utilizing this type of information is and must
be the sole responsibility of the builder/user. Many
variables beyond the control of The Lincoln Electric
Company affect the results obtained in applying this

Table B.2 Procedure Guidelines for Stainless Steel

.035 E308LSi 98/2 Ar/O

Wire Feed Speed Peak Bkgnd

135 IPM Low Norm 2 -- -- -­150 Low Norm 3.5 Med Norm 4.5
200 Low Norm 5 Hi Norm 5.5
250 Med Norm 5.5 Hi Norm 6.5
300 Med Norm 6 Hi Norm 7
350 Med Norm 6.5 Hi Norm 7.5
400 Med Norm 7 Hi Norm 7.7
450 Med-Hi Norm 7.5 Hi Norm 8
500 Med-Hi Norm 8 Hi Norm 8.1
550 Med-Hi Norm 8.5 -- -- -­600 Med-Hi Norm 9 -- -- -­650 Med-Hi Norm 9.5 -- -- --

type of information. These variables include, but are
not limited to, welding procedure, plate chemistry and
temperature, weldment design, fabrication methods
and service requirements.

These settings were developed for joints in the flat or
horizontal position. Out-of-position work will require
adjustments to these procedures.

To tighten or stiffen the arc, try decreasing the Peak
setting. To widen or soften the arc, try increasing the
Peak setting.

2

Arc Length

.045 E308LSi 98/2 Ar/O

Peak Bkgnd

2

Arc Length

JAN97

Table B.3 Procedure Guidelines for Mild Steel

.035 L-56 90/10 Ar/CO

Wire Feed Speed Peak Bkgnd

100 IPM -- -- -- Low Norm 5.1
125 -- -- -- -- -- -­150 Low Norm 4.5 Med Norm 6.2
200 Low Norm 5.5 Med Norm 7
250 Low Norm 6 Med Norm 7.5
300 Low Norm 6.4 Med Norm 8
350 Low Norm 7 Med Norm 8.5
400 Low Norm 7.5 Med Norm 9
450 Low Norm 8.1 Med Norm 9.5
500 Med Norm 8.2 -- -- -­550 Med Norm 8.4 -- -- -­600 Med Norm 8.5 -- -- -­650 Med Norm 9 -- -- -­700 Med Norm 9.5 -- -- --

MIG PULSER

2

Arc Length

.045 L-56 90/10 Ar/CO

Peak Bkgnd

2

Arc Length

C-1

MAINTENANCE

GENERAL MAINTENANCE

No regular or periodic maintenance is required for the
MIG Pulser. As with any welding equipment, occa­sionally clean the exterior of the unit with a low pres­sure airstream or a damp cloth. This keeps the front
and rear nameplates in a readable condition. Replace
any nameplates that become illegible.

C-1

MIG PULSER

D-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by 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
malfunctions. Simply follow the three-step
procedure listed below.

D-1

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos­sible symptoms that the machine may exhib­it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: engine problems, function prob­lems and output problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con­tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with­out removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF
ACTION

If you have exhausted all of the items in step

2. Contact your Local Lincoln Authorized
Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

MIG PULSER

D-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed througout this manual

D-2

PROBLEMS

(SYMPTOMS)

The MIG PULSER does not give a
satisfactory Weld.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

PROBLEMS

1. Incorrect settings at the V300.
Make sure the V300 switches are
set in the proper positions. See

V300 SETTINGS

Operation section of this manual.

2. Output Cables are either too long
or of improper size. See

PUT CABLES FOR PULSE
WELDING

tion of this manual.

3. The control cable may be extend­ed too long. Do not use more
than one optional 25 foot control
cable extension.

4. There may be high frequency
interference. Refer to the

FREQUENCY INTERFERENCE
PROTECTION

Installation section of this manual
for proper installation guidelines.

in the

OUT-

in the Installation sec-

HIGH

section in the

RECOMMENDED

COURSE OF ACTION

Contact your Local Lincoln Authorized
Field Service Facility for technical

troubleshooting assistance.

The voltmeter on the wire feeder (if
equipped) will not display.

1. This is normal. The wire feeder
voltmeter will not display since
there is no 21 lead in the feeder
connection.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

MIG PULSER

E-1

DIAGRAMS

WIRING DIAGRAM - MIG PULSER

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1-5-96

E-1

S21978

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Note: This diagram may not be totally applicable to every code covered by this manual. The diagram specific to your

machine is pasted inside one of the enclosure panels.

JAN97

MIG PULSER

L

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WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.