RETURN TO MAIN MENU IM555 MIG PULSER For use with machines having Code Numbers: March, 1999 10213 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS For Gasoline Engines: The engine exhaust from For Diesel Engines: Diesel engine exhaust and this product contains chemicals known to the some of its constituents are known to the State State of California to cause cancer, birth defects, of California to cause cancer, birth defects, and or other reproductive harm. other reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.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. 3.b.
iii iii SAFETY 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. 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.
iv iv SAFETY 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.
v v Thank You 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! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi TABLE OF CONTENTS Page SAFETY .......................................................................................................................................i-iv INSTALLATION................................................................................................................Section A TECHNICAL SPECIFICATIONS...........................................................................................A.1 SAFETY PRECAUTIONS...............................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - MIG PULSER INPUT Model Description K954-1 MIG Pulser Volts 42 VAC OUTPUT Amps Frequency 1A 50/60Hz Output Frequency Range Peak Current Settings Background Current Settings Pulse Width 20 to 300 Hz 250, 325 or 400 A 40 or 80 A 2 mS PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH 2.5 in. 5.0 in. 7.0 in. 64(mm) 127(mm) 178(mm) WEIGHT 3 lbs (1.4 kg) (without cables) OPTIONS/ACCESSORIES (K955-25) 25 ft. (7.
A-2 A-2 INSTALLATION 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. 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).
A-3 A-3 INSTALLATION 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.
B-1 OPERATION B-1 SAFETY PRECAUTIONS GENERAL DESCRIPTION Read entire section before operating this unit. Additionally, read the V300 operator’s manual before operating this unit. 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.
B-2 B-2 OPERATION DESIGN FEATURES AND ADVANTAGES LIMITATIONS •Simple controls make this unit easy to set up and adjust. 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 Output Cables for Pulse Welding section in the Installation chapter for limitations.
B-3 OPERATION B-3 V300 SETTINGS OPERATION GUIDELINES 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 suggested steps for initially establishing a welding procedure are as follows: 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.
B-4 B-4 OPERATION type of information. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. 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.
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.
D-1 TROUBLESHOOTING D-1 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.
D-2 D-2 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION PROBLEMS The MIG PULSER does not give a satisfactory Weld. 1. Incorrect settings at the V300. Make sure the V300 switches are set in the proper positions. See V300 SETTINGS in the Operation section of this manual. 2. Output Cables are either too long or of improper size.
E-1 E-1 DIAGRAMS 1-5-96 S21978 WIRING DIAGRAM - MIG PULSER , , , , 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.
LINCOLN ELECTRIC SERVICE MANUALS Now Available ...The following Service Manuals These are comprehensive single sources of information relative to Installation, Operation, Maintenance, Accessories, Theory of Operation, Replacement Parts, Electrical Diagrams and Extensive Troubleshooting. ORDER FROM: Technical Service Group-Customer Service Dept. Lincoln Electric Company 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 All orders must be pre-paid (US Funds Only): Please allow up to 4 weeks for delivery.
Now Available...12th Edition The Procedure Handbook of Arc Welding New Lessons in Arc Welding This printing will go fast so don’t delay. Place your order now using the coupon below. Lessons, simply written, cover manipulatory techniques; machine and electrode characteristics; related subjects, such as distortion; and supplemental information on arc welding applications, speeds and costs. Practice materials, exercises, questions and answers are suggested for each lesson.
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● 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- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
