Lincoln Electric IM736 User Manual

IM736-D

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POWER MIG

For use with machine Code Numbers: 10562, 10952, 10958, 11000, 11097, 11098

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.

For use with machine

™

300

February, 2004

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

OPERATOR’S MANUAL

Copyright © 2004 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel 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 & 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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

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
welding 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, 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
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.

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.

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.

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.

5.e. Also see item 1.b.

vapors

Mar ‘95

to

iii

SAFETY

4

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.

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.

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.

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.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

vv

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

vi

TABLE OF CONTENTS

Page

________________________________________________________________________

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ...............................................................................................................A-2

Uncrating the POWER MIG 300...........................................................................................A-2

Location................................................................................................................................A-2

Input Power, Grounding and Connection Diagrams .....................................................A-2, A-3

Gun and Cable Installation ...................................................................................................A-4

Shielding Gas .........................................................................................................A-4 thru A-5

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Definition Of Welding Modes...............................................................................................B-1

Common Welding Abbreviations ..........................................................................................B-1

Product Description ..............................................................................................................B-2

Controls and Settings ...................................................................................................B-2, B-3

Setting and Configuring the POWER MIG 300 for welding ..................................................B-4

Multi-Process Panel Functions .....................................................................................B-5, B-6

Wire Drive Roll .....................................................................................................................B-7

Procedure for Changing Drive and Idle Roll Sets................................................................B-8

Wire Reel Loading................................................................................................................B-8

Mounting of 10 to 44 lbs. Spools ..........................................................................................B-8

Feeding Wire Electrode........................................................................................................B-9

Idle Roll Pressure Setting.....................................................................................................B-9

Avoiding Wire Feeding Problems .........................................................................................B-9

Special Welding Processes Available ................................................................................B-10

Pulse On Pulse, and Benefits of Pulse On Pulse...............................................................B-11

Power Mode .......................................................................................................................B-12

________________________________________________________________________________

Accessories ....................................................................................................................Section C

Drive Roll Kits.......................................................................................................................C-1

Aluminum Feeding Kit .........................................................................................................C-1

Readi-Reel Adapter..............................................................................................................C-1

Dual Cylinder Mounting Kit...................................................................................................C-1

Alternative Magnum GMAW Gun and Cable Assemblies ....................................................C-1

Magnum Gun Connection Kit ..............................................................................................C-1

Spool Gun Prince

Push-Pull Feeding Connection Adapter Kit..........................................................................C-2

Making a Weld with the Prince XL or Cobra Gold Torch Installed .......................................C-2

________________________________________________________________________________

Maintenance....................................................................................................................Section D

Safety Precautions, General Maintenance...........................................................................D-1

Drive Rolls and Guide Plates ...............................................................................................D-1

Contact Tip and Gas Nozzle Installation ..............................................................................D-1

Gun Tubes and Nozzles, Gun Cable Cleaning ....................................................................D-1

Liner Removal and Replacement.........................................................................................D-2

________________________________________________________________________________

Troubleshooting .............................................................................................................Section E

How to Use Troubleshooting Guide .....................................................................................E-1

Troubleshooting .....................................................................................................E-2 thru E-5

Fault Codes ..........................................................................................................................E-6

Push / Pull Gun Wire Feeder Troubleshooting ....................................................E-7 thru E-10

________________________________________________________________________________

Diagrams..........................................................................................................................Section F

Wiring Diagrams and Dimension Print ...................................................................F-1 thru F-5

________________________________________________________________________________

Parts Manual ...................................................................................................................Appendix

POWER MIG 300 Parts Pages .............................................................................P409 Series

Magnum 300 & 400 GMAW Gun, Connector Assembly.....................................P202-C Series

________________________________________________________________________________

TM

XL.........................................................................................................C-1

vi

A-1 A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – POWER MIG 300

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency

208/230/460/575/60 Hz 48/43/22/17 Amps 72/62/31/25 Amps

Input Current @ 230Amp Rated Output Input Current @ 300 Amp Rated Output

RATED OUTPUT

Input

Voltage Duty Cycle Amps Volts at Rated Amperes

208 40% 300 Amps 32 Volts
230/460/575 60% 300 Amps 32 Volts
208/230/460/575 100% 230Amps 29 Volts

OUTPUT

Welding

Current Range (Continuous) Maximum Open Circuit Voltage Welding Voltage 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 Fuse

Frequency (Hz) 29 Volts 32 Volts AWG (IEC) or

(100% Duty Cycle) (60% Duty Cycle)

208/60* 48 A 72 A 6 (16 mm2) 90 A

230/60 43 A 62 A 6 (16 mm
460/60 22 A 31 A 10 (6 mm2) 50 A
575/60 17 A 25 A 12 (2.5 mm2) 35 A

Sizes (MM

2

)

2

) 80 A

Breaker Size

NOTE: Use #10 AWG Grounding Wire
*For 208V Input ONLY: The duty Cycle Rating at 300 Amps is 40%

PHYSICAL DIMENSIONS

Height Width Depth Weight

31.79 in 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

A-2

INSTALLATION

A-2

Read entire installation section before starting
installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live
parts or electrode with skin or
wet clothing.

• 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 volt­age (wire) welder.

- DC manual (stick) welder.

- AC welder with reduced voltage
control.

• Do not operate with panels
removed.

• Disconnect input power before
servicing.

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing
zone and general area.

WELDING SPARKS can
cause fire or explosion.

• Keep flammable material away.

• Do not weld on closed contain­ers.

ONLY QUALIFIED PERSONNEL SHOULD
INSTALL, USE OR SERVICE THIS EQUIP­MENT.

UNCRATING THE POWER MIG 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 pas­sages and cause overheating.

INPUT POWER, GROUNDING AND
CONNECTION DIAGRAMS

1. Before starting the installation, check with the local
power company if there is any question about
whether your power supply is adequate for the volt­age, 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

ARC RAYS can burn eyes
and skin.

• Wear eye, ear and body protec­tion.

Observe all safety information through­out this manual.

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

POWER MIG 300

A-3

INSTALLATION

FIGURE A.1 — Triple Voltage Machine Input Connections

A-3

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 quali­fied electrician connect the receptacle or cable to
the input power lines and the system ground per
the U.S. National Electrical Code and any applica­ble 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 following dia­gram. The center contact in the receptacle 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

A-4

INSTALLATION

A-4

GUN AND CABLE INSTALLATION

A Magnum 300 gun and 15Ft.(4.6m) cable
(12Ft.(3.7m) for Codes 11000 and below) are provid­ed with the POWER MIG 300. A Magnum cable liner
for .035-.045" (0.9-1.2 mm) electrode and contact tips
for .035” (0.9mm) and .045” (1.2mm) are included for
15Ft..

WARNING

Turn 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.

3. Lay gun and cable out straight on a flat surface.
Loosen set screw of the connector on the back end
of the gun.

4. Insert the untrimmed Liner into the back end of the
gun.

5. Seat Liner bushing into back of gun. Secure Liner
by tightening set screw. Do not install the gas dif­fuser at this time.

6. Lay the cable straight and trim Liner to 9/16”.
Remove burrs.

7. Secure the gas diffuser into the tube.

GUN & 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 the com­partment 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

2

an inlet gas hose are factory provided with the
POWER MIG 300.

WARNING

CYLINDER may explode if
damaged.

• Gas under pressure is explosive. Always
keep gas cylinders in an upright position
and always keep chained to undercarriage
or stationary support. See American
National Standard Z-49.1, “Safety in
Welding and Cutting” published by the
American Welding Society.

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 A.3

FEEDR END

BRASS CABLE
CONNECTOR

INSULATION TUBE

MOLDED GAS PLUG

SET SCREW

LINER ASSEMBLY (LINER BUSHING TO BE SEATED
TIGHT AGIANST BRASS CABLE CONNECTOR)

CABLE HANDLE

CLAMPING SCREW

POWER MIG 300

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.

GUN HANDLE

SET SCREW

GAS DIFFUSER

NOZZLE INSULATION

GAS NOZZLE

GUN TUBE

9/16 (14.3mm)

LINER TRIM
LENGTH

A-5

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.

INSTALLATION

WARNING

Be sure to keep your face away from the valve
outlet when “cracking” the valve.

4. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench.

NOTE: If connecting to 100% CO2cylinder, insert
regulator adapter between regulator and cylinder
valve. If adapter is equipped with a plastic washer,
be sure it is seated for connection to the CO
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.

2

cylin-

A-5

6. Before opening the cylinder valve, turn the regula­tor adjusting knob counterclockwise until the
adjusting spring pressure is released.

7. Standing to one side, open the cylinder valve slow­ly a fraction of a turn. When the cylinder pressure
gauge pointer stops moving, open the valve fully.

WARNING

Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
stand to one side.

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

8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making the weld.

POWER MIG 300

B-1

OPERATION

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.

• Always wear dry insulating
gloves.

B-1

COMMON WELDING ABBREVIA­TIONS

WFS

• Wire Feed Speed

CC

• Constant Current

CV

• Constant Voltage

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 contain­ers.

ARC RAYS can burn eyes
and skin.

• Wear eye, ear and body protec­tion.

Observe all safety information throughout
this manual.

DEFINITIONS OF WELDING MODES

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

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 cor­rect voltage and amperage based on the wire feed
speed (WFS) set by the operator.

POWER MIG 300

B-2

OPERATION

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 con­stant, or vice versa.

All of the other mode numbers designated as "CV" are
synergic. Again, WFS is shown on the left meter and
voltage is shown on the right meter. However, in using
these modes, the WFS is preset and the voltage is
preset only once. Now, when the WFS is changed, the
voltage will change with it, so that the arc appearance
and arc length will stay the same without the necessity
to re-adjust the voltage.

The modes shown as "GMAW-P" or " GMAW-PP" are
all synergic pulsed modes. In these modes WFS is
shown on the left meter and "Trim" is shown on the
right meter. The user adjusts WFS to obtain an arc
with the correct arc energy for the material thickness
being welded. The Trim, which is adjustable from val­ues of –1.5 to 0 (OFF) and up to +1.5 controls the arc
length. Higher values of Trim give longer arc lengths.
Once the user has adjusted the Trim for one WFS, the
power supply will synergically change many variables
so that, as the WFS is changed, the arc length and
arc appearance will remain the same. The synergic
modes are usable with both push and push – pull
torches, as described later in this Manual. When using
a spool gun, however, although the synergic pulsed
modes are still accessible, they must be used in a
non-synergic manner as described in the Accessory
Section.

B-2

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 dis­played 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 dis­plays the set WFS (CV modes) or Amp (CC
modes) value.

Figure B.1

The digital microcomputer based control system
allows easy and accurate adjustment of weld parame­ters through the multi-process panel located on the
front of the machine. The POWER MIG 300 is
equipped with a 6-pin and 7-pin connector to allow
operation of a push-pull gun for feeding aluminum
wires, a spool gun, remotes, and a foot amptrol.

POWER MIG 300

B-3

OPERATIONS

B-3

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 oper­ation, 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 volt­age to 95% of the recommended voltage.

• During Welding, the meter displays actual aver­age 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 dis­plays the set Voltage (GMAW, FCAW) or Trim
(GMAW-P) value.

CC Processes

• The meter displays the status of the output.

• When output is enabled, the meter will display "ON."

• When there is no output, the meter will display "OFF."

3. OUTPUT CONTROLS - The POWER MIG 300 has 2
encoder knobs to adjust weld parameters.

• Each encoder changes the displayed value of the meter
located directly above that encoder.

• In CC-GTAW modes, the left encoder sets the maxi­mum welding current. Full depression of a foot or hand
amptrol results in the preset level of current.

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 selec­tion will be shown on the display. The possible selections
are:

• Weld Mode (Process selection choices)

• Preflow / Postflow

• Run-In

• Start

• Arc Control

• Crater

• Burnback

• Spot

Only one LED will be illuminated at any time. The Weld
Mode attribute will always be a valid selection (the other
attributes may not be available in all processes).

5A. SELECT Toggle Switch

• This switch toggles through the 8 selections detailed
above the switch.

• A red LED is located next to each possible selection
and is illuminated when that choice can be changed.

5B. Display Meter

• This meter displays the active weld mode (a set of
weld parameters that have been determined to pro­vide 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 parame­ter 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 illu­minated, this switch is changing the weld mode of the
machine. The most commonly used modes are dis­played in the chart on the right half of the Multi­Process 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

Choice of weld parameters
that can be adjusted.
Complete descriptions of
each parameter are found

}

later in this section.

• In CC-Stick and CC-GTAW, the right encoder activates
and de-activates the output. Turning the encoder clock­wise 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.

POWER MIG 300