Lincoln Electric IM859 User Manual
IM859
11147
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POWER MIG®350MP
For use with machine 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.
For use with machine
May, 2012
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATORʼS MANUAL
Copyright © 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.
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 ma y 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 within applicable OSHA PEL and
ACGIH TLV limits 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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
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.d. 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.
vapors
to
5.e. 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.f. Also see item 1.b.
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
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.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use on ly com pr essed 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. Re ad and foll ow the inst ru ctions o n c ompressed 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. Ins tall 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.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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 LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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 lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
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_________________________________________________________________________
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
Your Product”. 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 “Support” and then “Register
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
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
Installing TIG Torch ......................................................................................................A-5, A-6
________________________________________________________________________________
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
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
Wire Drive Configuration.............................................................................................B-9, B-10
Avoiding Wire Feeding Problems .......................................................................................B-10
Special Welding Processes Available ................................................................................B-11
Pulse On Pulse, and Benefits of Pulse On Pulse...............................................................B-12
Power Mode, TIG Welding .................................................................................................B-13
________________________________________________________________________________
Accessories ....................................................................................................................Section C
Drive Roll Kits.......................................................................................................................C-1
Aluminum Feeding Kit, Readi-Reel Adapter ........................................................................C-1
Dual Cylinder Mounting Kit...................................................................................................C-1
Magnum GMAW Gun and Cable Assemblies ......................................................................C-1
Magnum Gun Connection Kit ..............................................................................................C-1
Spool Gun Prince
TM
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, F-2
________________________________________________________________________________
Parts Manual ...................................................................................................................Appendix
POWER MIG
®
350MP Parts Pages ......................................................................P512 Series
Magnum 300 & 400 GMAW Gun, Connector Assembly.....................................P202-C Series
________________________________________________________________________________
®
350MP ...................................................................................A-2
®
350MP for welding...........................................B-4
XL.........................................................................................................C-1
vi
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – POWER MIG®350MP
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency
208/230/460/575/50/60 Hz 50/48/25/20 Amps 76/64/37/29 Amps
Input Current @ 230Amp Rated Output Input Current @ 300 Amp Rated Output
RATED OUTPUT
Input Voltage/Frequency Hz
208/60 40% 300 Amps 32 Volts
230/460/575/60 60% 300 Amps 32 Volts
208/230/460/575/60 100% 230 Amps 29 Volts
208/230/460/575/50 40% 300 Amps 32 Volts
208/230/460/575/50 100% 230 Amps 29 Volts
Duty Cycle Amps Volts at Rated Amperes
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 @ 350Amps @ 75°C Copper Wire Fuse
Frequency (Hz) 29 Volts 32 Volts 34 Volts AWG (IEC) or
(100% Duty Cycle) (60% Duty Cycle)
208/50*/60** 50A 76A 93A 6 (16 mm2) 100 A
230/50*/60 48A 64A 80A 6 (16 mm2)80 A
460/50*/60 25A 37A 45A 10 (6 mm
575/50*/60 20A 29A 34A 12 (2.5 mm2)35 A
(40% Duty Cycle)
Sizes (MM2)
2
Breaker Size
)50 A
Wire the Welder to Dedicated circuit branch.
NOTE: Use #10 AWG Grounding Wire.
*For 50Hz operation: The duty Cycle Rating at 300 Amps is 40%. The duty cycle rating at 350 Amps is 30%.
**For 208V Input: 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®350MP
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
350MP
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
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
®
350MP is supplied connected
®
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protection.
Observe all safety information throughout this manual.
-----------------------------------------------------------
POWER MIG®350MP
A-3
INSTALLATION
FIGURE A.1 — Triple Voltage Machine Input Connections
A-3
3. The POWER MIG®350MP 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.
For input voltages above 230V, remove 208/230V
input cord supplied and replace with direct hard
wire connection to the fuse box.
For 208V Canadian installations, remove the plug
and connect directly to the fuse box in accordance
with the Canadian Electric Code.
AUXILIARY POWER RECEPTACLES
(15 Amp, 120 Volt Receptacle) The receptacle is UL
and CSA approved.
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®350MP
A-4
INSTALLATION
A-4
GUN AND CABLE INSTALLATION
A Magnum 300 gun and 15Ft.(4.6m) cable are provided with the POWER MIG
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..
®
350MP. A Magnum cable
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.
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
®
350MP.
WARNING
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.
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
CABLE HANDLE
BRASS CABLE
CONNECTOR
INSULATION TUBE
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.
Install shielding gas supply as follows:
1. Set gas cylinder on rear platform of POWER MIG
350MP. 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
GUN TUBE
®
MOLDED GAS PLUG
SET SCREW
LINER ASSEMBLY (LINER BUSHING TO BE SEATED
TIGHT AGIANST BRASS CABLE CONNECTOR)
CLAMPING SCREW
POWER MIG®350MP
SET SCREW
GAS DIFFUSER
NOZZLE INSULATION
GAS NOZZLE
9/16 (14.3mm)
LINER TRIM
LENGTH
A-5
INSTALLATION
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.
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% CO
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
union nuts securely with a wrench.
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.
®
350MP rear fitting, and tighten the
cylinder, insert
2
2
cylin-
INSTALLING TIG TORCH
The POWER MIG®350MP is programmed to allow it
to be used as a DC TIG welder. The following information addresses the installation of an air-cooled TIG
torch with separate power cable and a separate gas
hose (2-cable style).
Connecting TIG Torch:
(See Figure A.4)
WARNING
ELECTRIC SHOCK can kill.
Turn off welder before adding or
installing accessory items.
-----------------------------------------------------------
1.
Tightly
2. Tightly connect the Power cable to Negative stud (-).
3
. Connect the gas supply line to the connector on the
front of the machine.
4. After following the previous instructions of installing
the cylinder and regulator, locate gas connection on
the back of the machine which is marked Spool
GUN or TIG Torch and connect gas line from
Cylinder and Regulator as shown in Figure A.5.
5. Connect the remote control receptacle from the
Foot Amptrol(Optional) to the remote control receptacle on the machine.
secure work lead to positive stud (+).
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®350MP
A-6
TIG
TORCH
GAS
HOSE
POWER
CABLE
WORK
CABLE
WORK
PIECE
TO NAGATIVE
STUD(-)
WORK
CLAMP
CONNECTOR
TO GAS SUPPLY
INSTALLATION
FIGURE A.4
TO POSITIVE
STUD(+)
FOOT
AMPTROL
(OPTIONAL)
POSITIVE STUD (+)
NEGATIVE STUD (-)
GAS SUPPLY
CONNECTION
TO REMOTE
CONTROL
RECEPTACLE
REMOTE CONTROL
RECEPTACLE
A-6
SPOOL GUN AND
TIG TORCH
GAS CONNECTION
FIGURE A.5
GAS REGULATOR
GAS CYLINDER
GAS LINE
FROM CYLINDER
AND REGULATOR
POWER MIG®350MP
B-1
OPERATION
Read entire Operation section before
operating the POWER MIG
®
350MP.
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®350MP
B-2
OPERATION
B-2
PRODUCT DESCRIPTION
The POWER MIG®350MP is a complete semiautomatic multi-process DC arc welding machine offering
CV and CC DC welding. It is rated for 350 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 0.5 to 1.5, 1.00(Nominal) 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.
Other features
Optional kits are available for push-pull welding, spool
gun operation, push feeding of 3/64 aluminum with the
standard POWER MIG
A Dual Cylinder Mounting Kit is also offered.
®
350MP gun and wire feeder.
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
1
4
3
2
5
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
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.
®
350MP is
POWER MIG®350MP
5B
5A
5C
6
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