Red-D-Arc E300 User manual

RED-D-ARC
E300
IM675
May, 2000
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder 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 machines having Code Numbers: 10638
North America’s Largest Fleet of Welding Equipment
1-800-245-3660
OPERATOR’S MANUAL
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

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 vaporiz-
ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
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.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.
i
SAFETY
i
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.
WARNING
Mar ‘95
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.
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.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
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 Diesel Engines The Above For Gasoline Engines

ii
SAFETY
ii
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.
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.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
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. Mar ‘95

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.
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.
iii
SAFETY
iii
Mar ‘95
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. 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 though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.

iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûretéspecifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûretégénérales suiv-
antes:
SûretéPour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits àl’électrode et àla piéce sont sous tension
quand la machine àsouder 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 couchépour 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 àsouder 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 àdeux machines àsouder
parce que la tension entre les deux pinces peut être le
total de la tension àvide des deux machines.
f. Si on utilise la machine àsouder 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 ray-
onnement 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 àproximitéau
soudage àl’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, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécuritédans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones oùl’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dûaux étincelles.
7. Quand on ne soude pas, poser la pince àune endroit isoléde
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 lev-
age, 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 SÛRETÉPOUR
LES MACHINES ÀSOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier àla terre le chassis du poste conformement au code de
l’électricitéet aux recommendations du fabricant. Le dispositif
de montage ou la piece àsouder doit être branchéàune
bonne mise àla terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux àl’interieur de poste, la debranch-
er àl’interrupteur àla boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûretéàleur
place.
Mar. ‘93

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!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
vv

vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions.................................................................................................A-2
Location ..........................................................................................................A-2
Input Connections ...........................................................................................A-2
Stacking ..........................................................................................................A-3
Installation of Field Installed Options ..............................................................A-3
Output Cable Size and Connection.................................................................A-3
Operation .........................................................................................................Section B
General Description...............................................................................................B-1
Recommended Processes and Equipment ...........................................................B-1
Design Features ....................................................................................................B-1
Duty Cycle ............................................................................................................B-1
Auxiliary Power ....................................................................................................B-1
Control Operation ..................................................................................................B-1
Accessories.....................................................................................................Section C
General Options / Accessories..............................................................................C-1
Field Installed Options ..............................................................................................C-1
Maintenance.....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Maintenance ............................................................................................D-1
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide .............................................................................E-2,E-3,E-4
Wiring Diagrams..............................................................................................Section F
Parts Lists................................................................................................................P365

A-1
INSTALLATION
RED-D-ARC E300
A-1
TECHNICAL SPECIFICATIONS - RED-D-ARC E300 (TYPE K1688-1)
RATED OUTPUT - WELDER
RATED INPUT - WELDER
HEIGHT WIDTH DEPTH WEIGHT
27.00 in.* 9.00 in. 21.50 in. 350 lbs. (159 kg )
686 mm* 483 mm 546 mm (159 kg)
OUTPUT
Current Range Volts at Rated Amps Duty Cycle Max. OCV
DC 250 Amps
40-250 amps 30 volts 30% 70 volts
Auxiliary Power
15 Amps @ 115VAC
100 % Duty Cycle
PHYSICAL DIMENSIONS
AC Input Frequency 60 Hz
Input Power Standard Voltages 230/460/575
Rated Input Current (230V 60Hz) 86 amps
Idle Input Current (230V) 6.2 amps
Power Factor (200 Amp Load) 69.0
*(Lift Hook, add 3.12 in.- 80 mm)

A-2
INSTALLATION
RED-D-ARC E300
A-2
INSTALLATION
Safety Precautions
•Connect the E300 grounding terminal located under
the reconnect panel (marked ) to a good electri-
cal ground per the U.S. National Electrical Code and
any applicable local codes.
•Turn the power switch on the E300 “OFF”before
connecting or disconnecting output cables or other
equipment.
•Only qualified personnel should perform this installa-
tion.
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.
------------------------------------------------------------------------
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.
------------------------------------------------------------
See additional warning information at the
front of this operator’s manual.
-----------------------------------------------------------
WARNING
Location
The machine should be located in a clean, dry place
where there is free circulation of clean air such that air
movement in the back and along the sides will not be
restricted. Dirt and dust that can be drawn into the
machine should be kept to a minimum. Failure to
observe the precautions can result in excessive
operating temperatures and nuisance shutdown of the
machine.
Input Connections
Be sure the voltage, phase and frequency of the input
power is as specified on the welder rating plate locat-
ed on the rear panel of the machine. Either a single
phase or one phase of a three phase line can be
used.
Have a qualified electrician install the machine per the
following instructions:
Remove the input access panel on the rear panel.
Route the input power lines through the hole in the
rear panel. Lug the input leads with a ring terminal for
a 1/4”(6mm) screw. Connect lugged leads to L1 and
L2 of the reconnect panel per the diagram pasted to
the inside of the input access panel. Input connection
must conform to the U.S. National Electrical Code and
all local codes.
Models designed for two or three input voltages are
shipped connected for the highest voltage.
Reconnect instructions are on the diagram pasted to
the inside of the input access panel. Consult rating
plate on the rear panel for machine input voltage rat-
ing.
The welder frame must be grounded. A stud marked
with the symbol located under the reconnect
panel is provided for this purpose. See the U.S.
National Electrical Code for details on proper ground-
ing methods.
Fuse the input circuit with the recommended super lag
fuses. Choose an input and grounding wire size accord-
ing to local codes or use the following table. “Delay type”
circuit breakers may be used in place of fuses. Using
fuses or circuit breakers smaller than recommended may
result in “nuisance”tripping from welder inrush currents
even if not welding at high currents.
230 60 70 #6 #8 90
460 60 35 #10 #10 45
575 60 28 #12 #10 40
Input Amps
Volts Hz.
Grounding
Conductor
Supply
Conductor
Copper Wire Sizes
75°C in Conduit
Fuse Size
(Super Lag)
RECOMMENDED INPUT WIRE, GROUND WIRE AND FUSE SIZES 200 Amp Output and 50% Duty Cycle

A-3
INSTALLATION
RED-D-ARC E300
A-3
STACKING
Installation of Field Installed Options
For installation of compatible field installed options,
see Field Installed Options section, and refer to the
instructions included with those options.
Output Cable Size and Connection
The output leads are connected to the output termi-
nals marked ‘+”and “-”. They are located at the lower
right and lower left corners of the front panel. The
E300 provides 1/2”studs for weld cable connections.
Minimum cable sizes recommended are listed in the
table below.
CABLE SIZES FOR COMBINED LENGTHS OF
COPPER ELECTRODE AND WORK CABLES
0-100 Ft.
100-150 Ft.
150-200 Ft.
200-250 Ft.
200 Amps
50% Duty Cycle
3 (30mm2)
2 (35mm2)
1 (45mm2)
1/0 (55mm2)
250 Amps
30% Duty Cycle
3 (30mm2)
2 (35mm2)
1 (45mm2)
1/0 (55mm2)
FALLING EQUIPMENT can cause
injury.
•Do not lift this machine using lift bale if
it is equipped with a heavy accessory
such as undercarriage or gas cylinder.
•Lift only with equipment of adequate lifting capacity.
•Be sure machine is stable when lifting.
•Do not stack.
•Do not stack on top of any other type machine.
---------------------------------------------------------------------
WARNING
ELECTRIC SHOCK can kill.
•Turn the power switch of the
welding power source “OFF”
before connecting or disconnect-
ing output cables.
------------------------------------------------------------
WARNING

B-1
OPERATION
RED-D-ARC E300
B-1
GENERAL DESCRIPTION
The E300 is a single phase constant current arc weld-
ing power source available in a DC output model only.
Designed for stick welding, it may also be used for
TIG welding when used with the K930-1 Tig Module.
A 15 amp 115 volt AC, Auxiliary Power duplex recep-
tacle, with circuit breaker protection is provided.
RECOMMENDED PROCESSES AND
EQUIPMENT
DC Constant Current Welding
TIG Welding
The K930-1 Tig Module can be used with this
machine to provide high frequency stabilization and a
gas valve for TIG welding. It operates on 115V 50/60
Hz power. A water valve (for water cooled TIG torch-
es) is available as an option.
DESIGN FEATURES
•Power On/Off switch.
•Continuous current control dials with exact welding
current needed for each job. Settings are precise
and free from creep.
•Spring loaded knob on the continuous current
control crank pulls out for easy adjustment and
snaps back out of the way when released.
•Recessed front panel protects controls.
•Large safety margins and protective circuits protect
rectifiers from transient voltages and high currents.
•Submersion dipping of assembled transformer and
choke in special sealing/insulating material gives
extra protection against moisture and corrosive
atmosphere.
•Outstanding Arc Stability - Transformer design pro-
vides pop-out-resistant welding.
•Reconnect panel is provided to permit changing
from one input voltage to another without reconnect-
ing transformer leads.
•Auxiliary Power-15 amps at 115 VAC
Be sure the E300 is properly installed, and that all
accessories are properly hooked up before attempting
operation.
DUTY CYCLE (WELD)
This machine is rated at a 30% duty cycle at 250
amps or 50% duty cycle at 200 amp output. Duty
cycle is based on a 10 minute period. Therefore,
the welder can be loaded at 200 amperes for 5
minutes out of each 10 minute period. Higher duty
cycles can be used at lower currents; see rating
plate information.
AUXILIARY POWER
•One 15 amp 115 VAC grounding duplex receptacle
is standard. Also provided is a receptacle cover and a
15 amp circuit breaker for Auxiliary circuit protection.
CONTROL OPERATION
•Current Control Handle
Rotating the hand wheel raises and lowers the
output current allowing the operator to dial the
desired current. Clockwise rotation reduces the
current while counter-clockwise rotation increases
the current. Turning the current control handle
also drives the output pointer at the bottom of the
nameplate which indicates the stick welding cur-
rent at NEMA arc volts.
•TIG Welding
The E300 with the optional Tig Module is an inex-
pensive equipment combination for part-time pro-
duction or repair TIG welding of aluminum, mag-
nesium, thin stainless steel and many space-age
metals. The E300 can be used for normal stick
electrode welding with the Tig Module attached.
The Tig Module includes high frequency genera-
tor, gas valve and needed controls. It operates
on 115V, 60 Hz AC power.
NOTE: Installation instructions are in the kit. (When
using the E300 with any other high frequency equip-
ment, an R.F. bypass capacitor must be installed.
Order Kit T12246.) To provide protection, the welder
grounding stud or frame must be connected to ground
(see instructions on grounding in Machine Installation
section). Also follow the grounding instructions given
in the Tig Module Instruction manual.
DC 40-250 Amps
DUTY CYCLE OUTPUT AMPS
100% 140 Amps
50% 200 Amps
30% 250 Amps
20% 300 Amps

C-1
ACCESSORIES
C-1
OPTIONS / ACCESSORIES
AND COMPATIBLE LINCOLN
EQUIPMENT
Field Installed Options
•Tig Module (K930-1)
Converts E300 into a TIG welder.
Request Bulletin E3.205 for full details.
•Standard Accessory Kit (K710)
Includes electrode holder, work clamp, electrode,
work cables, and headshield with lens and
coverplate.
RED-D-ARC E300

D-1
MAINTENANCE
D-1
RED-D-ARC E300
Safety Precautions
General Maintenance
1. The fan motor has sealed ball bearings which
requires no service.
2. In dusty locations dirt may clog the air channels
causing the welder to run hot. Under these
conditions carefully blow out the welder at regular
intervals.
3. Keep the electrode and work cable connection
tight.
4. Every twelve months or at the first indication of a
binding current pointer, turn the input power off
and remove the left case side. Wipe the pointer
guide bar clean and lubricate with graphite
grease.
5. When cleaning the current pointer, clean the
reactor quadrant teeth, drive gear and pinion.
Lubricate with graphite grease.
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.
------------------------------------------------------------------------
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.
------------------------------------------------------------
See additional warning information at the
front of this operator’s manual.
-----------------------------------------------------------
WARNING

E-1
TROUBLESHOOTING
E-1
RED-D-ARC E300
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes
possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE
CAUSE”lists the obvious external possibili-
ties that may contribute to the machine
symptom.
Step 3. RECOMMENDED COURSE OF
ACTION
This column provides a course of action for
the Possible Cause, generally it states to
contact your local Lincoln Authorized Field
Service Facility.
If you do not understand or are unable to
perform the Recommended Course of
Action safely, contact your local Lincoln
Authorized Field Service Facility.
HOW TO USE TROUBLESHOOTING GUIDE
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.
__________________________________________________________________________
WARNING

E-2
TROUBLESHOOTING
E-2
RED-D-ARC E300
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Rectifier Troubleshooting 1. Turn the input power off.
2. Disconnect all input and output
leads from the rectifier bridge.
3. Connect an ohmmeter between
the DC positive (red) terminal
and one of the Center AC termi-
nals. Note the ohmmeter read-
ing using the 10 to 100 scale.
4. Reverse the ohmmeter leads.
Note the readings.
5.
The reading taken in steps 3
and 4 should be different. If
the readings are the same and
near zero, the rectifier has
shorted. IF the readings are
the same and near full scale,
the rectifier has failed open.
6. Repeat steps 3, 4 and 5
between the DC positive (red)
terminal and each of the
Center AC terminals.
7. Repeat steps 3, 4 and 5
between the DC negative
(black) terminal and each of
the Center AC terminals.
NOTE: Since it is unlikely that all
rectifiers of a full wave bridge
would fail simultaneously, check
the test method and the ohmmeter
if the checking indicates that all
rectifiers have failed.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.

E-3
TROUBLESHOOTING
E-3
RED-D-ARC E300
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Welder will not weld.
Welder welds, but soon stops weld-
ing (DC only).
1. Line switch not turned “On”.
Supply line fuse blown.
2. Power circuit dead.
3. Broken power lead.
4. Wrong voltage.
5. Electrode or work lead loose or
broken.
6. Open transformer circuit.
1. Proper ventilation hindered.
2. Welder loaded beyond rating.
3. Fan motor inoperative.
4. Poor internal connections.
5. Excessive dust accumulation in
welder.
6. Bi-metallic thermostat dirty.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.

E-4
TROUBLESHOOTING
E-4
RED-D-ARC E300
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
RECOMMENDED
COURSE OF ACTION
Variable or sluggish welding.
Welder won’t shut off.
1. Poor work or electrode terminal
connection.
2. Current too low.
3. Low line voltage.
4. Welding leads too small.
5. Old and badly frayed welding
cables.
1. Line switch has failed
mechanically.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.

F-1
DIAGRAMS
F-1
RED-D-ARC E300
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
H1
L1 L2
TO GROUND PER NATIONAL ELECTRICAL CODE
INPUT
LEADS RECONNECT PANEL
X1
X2
X3
X4
MTR
LINE
SWITCH
POWER RECTIFIER CHOKE
AC1 AC2
(+)
(-)
LOW
MED
HIGH
SEE TABLE
BELOW FOR CORRECT
CONNECTION
ELECTRICAL SYMBOLS PER E1 37.
230/460/ 7
CONNECTIONS MUST BE TIGHTENED SECURELY.
H
H
DO NOT TOUCH ELECTRICALLY "HOT" PARTS SUCH AS OUTPUT TERMINALS
DO NOT OPERATE WITH COVERS REMOVED.
ONLY QUALIFIED PERSONNEL SHOULD INSTALL OR SERVICE THIS EQUIPMENT.
HIGH VOLTAGE
can kill
OR INTERNAL WINDINGS.
TURN THE INPUT POWER TO THE WELDER OFF USING THE DISCONNECT SWITCH AT THE FUSE BOX BEFORE INSTALLING OR SERVICING THIS MACHINE.
THROUGH THE INPUT CABLE PER NATIONAL ELECTRICAL CODE.
230
460
HIGH
H2
H3
H4
GROUNDING SCREW MUST BE CONNECTED TO A GOOD EARTH GROUND
LOW MED
OF H LEAD
BB
FAN MOTOR
NEGATIVE (-)
POSITIVE (+)
SUPPRESSOR CIRCUIT
RECTIFIER OVERLOAD
THERMOSTAT
G
11 VAC AUXILIARY RECEPTACLE
W
VOLTAGE SELECTOR LEAD (H ) POSITION
60 HZ
FOR INPUT VOLTS OF CONNECT H TO:
7
*
*
COLOR CODE
G - GREEN
W - WHITE
B - BLACK OR GRAY
9-9-99
S247 0
CONNECTED FOR HIGHEST INPUT VOLTAGE.
MACHINES ARE SHIPPED FROM FACTORY
15 AMP
WIIRING DIAGRAM-E300
S24750

F-2
NOTES
RED-D-ARC E300
F-2

F-3
NOTES
RED-D-ARC E300
F-3