Lincoln Electric IM693 User's Manual
Contents
1. ON POWER MIG 200 LINCOLN 5 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth co2. Do not weld on closed contain ers and skin e Wear eye ear and body protec tion 4 ARC RAYS can burn eyes NM Observe all safety information throughout this manual POWER MIG 200 LINCOLN 2 2 PRODUCT DESCRIPTION The POWER MIGTM 200 is a complete semiautomatic DC voltage arc welding machine built to meet NEMA specifications It combines a tapped transformer volt age power source with a constant speed wire feeder to form a reliable robust performance welding system A simple control scheme consisting of continuous full range wire feed speed control and 7 output voltage tap selections provides versatility with ease of use and accuracy Other features include a 2 51 mm O D wire reel spindle with adjustable brake an integral gas cylinder mounting undercarriage an adjustable Argon blend flow regulator with cylinder pressure gauge and inlet hose a 12 ft 3 6 m Magnum 250L GMAW gun and cable with fixed flush nozzle a 7 ft 2 1 m power cable with plug and a 10 ft 3 0 m work cable with clamp Optional Spool Gun and Adapter kit Dual Cylinder Mounting kit and Aluminum Feeding Kit for push feed ing with standard built in feeder are also available RECOMMENDED PROCESSES AND EQUIPMENT The POWER MIG 200 is recommended for GMA welding processes using 10 to 44 Ib 4 5 to 20 kg 2 51 mm 1 0 spools or Readi Reel coils with option al adapter of 025 through 04
3. Check that the gun is pushed all the way into gun mount and properly seated 1 The wire feed stops while weld ing When trigger is released and pulled again the wire feed starts Check the wire feed drive rolls and motor for smooth operation Check for restrictions in the wire feed path Check the gun and cable for restrictions Make sure gun liner and tip are correct for wire size being used Make sure drive rolls and guide plates are clean and are the correct size Check spindle for ease of rotation No control of wire feed speed Other machine functions are nor mal The wire feed speed control may be dirty Rotate several times and check if problem is resolved RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed POWER MIG 200 LINCOLN EM TROUBLESHOOTING ES Observe all Safety Guidelines detailed throughout this manual PROBLEMS
4. Innershield 3 8 ESO NoneReq d NR 211MP NoneReq d NR 211MP t Electrical Stickout 50 B 70 B 80 B 40 B 50 B 60 B Note Requires Mutiple Pass 75Ar 25CO DC 250 D 300 E 350 F 600G 500 G 100 CO DC 300 E 350 F 500G 75Ar25CO DC 200 E 225 250 G 250 G 250 G 90 C 110 0 90 C 1110 0 130 E 150 150 035 amp 045 NR 211 MP is only recommended for a maximun of 5 16 POWER MIG 200 LINCOLN il ACCESSORIES a DRIVE ROLL KITS Refer to Table C 1 for various drive roll kits that are available for the POWER MIG 200 The item in Bold is supplied standard with the POWER MIG 200 023 030 0 6 0 8 mm KP1696 030S 035 0 9 mm KP1696 035S 045 1 2 mm 1696 0455 Solid Steel KP1697 035C KP1697 045C Cored 035 0 9 mm 045 1 2 mm Aluminum 3 64 1 2 mm KP1695 3 64A TABLE C i 3 64 1 2 mm ALUMINUM FEEDING KIT K1703 1 This kit helps push feeding aluminum through stan dard machine feeder and gun It provides gun and wire drive conversion parts to weld with 3 64 1 2 mm aluminum wire 5356 alloy aluminum wire is rec ommended for best push feeding performance Kit includes drive rolls and wire guide plate for the wire drive liner and two contact tips for the gun along with installation instructions K363P READI REEL ADAPTER The K363P Readi Reel Adapter mounts to the 2 spin dle It is needed to mount the 22 30 Ib Readi Reels DU
5. JANYA 103NNOO3M HOLIMS ei oloanas 1 8 1 341024 D 39018 nouviao 5 19 1004S NON 3 03 Q3TIVISNI md POWER MIG 200 GIONTI0S Svo OX vu e WIRING DIAGRAMS ve o 9 Japoni ais YALIWOH VL veel vr YOLOANNOO 40 20E qv3TNON 3oNano3s vi oni 5 sx AVISONMEHL 1VISOWYHL ATanassy LES sanuodsNval ON ALIAVO NOLO3NNOO SLVOIONI ana Wu aay WI anis 3LIHM MYOM dYH LS HOLOnQNOO 3189 LY SNOLLO3NNOO GW31 SSYSASY ANY 440 LINN IHL Visa 9 2 JO 1 LV10d39NYHI OL 04 ALIMW10d 3008193713 IHL SMOHS SIHL 8l 3002 90102 ONIHAANNN ALIAVO TONLNOD UML ANY 31VIQ3ATWI 30 31949 ALNG ANY IN3ddno JHL HO AllOVdVO 40 38 318 VO NOTE 15912 3d STOSWAS 19110513 NOLLVNSONI IVH3N39 I 802 00 SIN H3MOd
6. Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s re
7. pops up and that the collar retainers fully engage the retaining ring groove on the spindle TO START THE WELDER Turn the Power Switch switch to ON This lights the red LED dis play lights With the desired voltage and wire speed selected oper ate the gun trigger for welder output and to energize the wire feed motor LINCOLN B 4 OPERATION B 4 FEEDING WIRE ELECTRODE WARNING When triggering the electrode and drive mecha nism are electrically hot relative to work and ground and remain hot several seconds after the gun trigger is released NOTE Check that drive rolls guide plates and gun parts are proper for the wire size and type being used Refer to Table C 1 in Accessories section 1 Turn the Readi Reel spool until the free end of the electrode is accessible 2 While securely holding the electrode cut off the bent end and straighten the first six inches If the electrode is not properly straightened it may not feed properly through the wire drive system 3 Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine Lift the cast idle roll assembly and allow it to sit in an upright position Leave the outer wire guide plate installed Manually feed the wire through the incoming guide bushing and through the guide plates over the drive roll groove Push a sufficient wire length to assure that the wire has fed into t
8. FROM EE C 1 Aluminum Feeding Kit Optional K1703 1 C 1 K363P Readi Reel Adapter issues e itk dignes ere C 1 Dual Cylinder Mounting Kit K1702 1 1 Alternative Magnum GMAW Gun and Cable Assemblies C 1 Magnum Gun Connection Kit Optional 466 6 C 1 Spool Gun and Adapter Kit Optional K1809 1 C 1 Making Weld with the Spool Gun Adapter Kit and Spool Gun Installed C 2 POWER MIG 200 LINCOLN vii MASTER TABLE OF CONTENTS FOR ALL SECTIONS cont Page l CIhpchru Section D Safety We ee EE D 1 General M intenharice u coire repente etie nt Ded ERR Re D 1 Drive Rolls and guide TUDOS AANEREN D 1 Contact Tip and Gas Nozzle Installation pp D 1 Gun Tubes and Nozzles is D 1 D 1 Liner Removal and Replacement D 2 Gun Handle Disassembly a n ER Ev e D 3 Troubleshooting eene nennt nennen Section How to Use Troubleshooting Guide enne E 1 Troubleshooting Guide 2 E 2 thru 4 Wiring Diagram and Dimension Print Section F Parts Manual Appendix POWER MIG 200 iere eur
9. MAGNUM 250L NOTE The variation in cable lengths prevents the interchangeability of liners between guns Once a liner has been cut for a particular gun it should not be installed in another gun unless it can meet the liner cutoff length requirement Liners are shipped with the jacket of the liner extended the proper amount 1 Remove the gas nozzle and nozzle insulator if used to locate the set screw in the gas diffuser which is used to hold the old liner in place Loosen the set screw with a 5 64 2 0 mm Allen wrench 2 Remove the gas diffuser from the gun tube 3 Lay the gun and cable out straight on a flat surface Loosen the set screw located in the brass connec tor at the feeder end of the cable and pull the liner out of the cable 4 Insert a new untrimmed liner into the connector end of the cable Be sure the liner bushing is sten cilled appropriately for the wire size bing used 5 Fully seat the liner bushing into the connector tighten the set screw on the brass cable connector the gas diffuser at this time should not be installed onto the end of the gun tube 6 With the gas diffusor still removed from the gun tube be sure the cable is straight and then trim the liner to the length shown in Figure D 1 Remove any burrs from the end of the liner 7 Screw the gas diffuser onto the end of the gun tube and securely tighten Be sure the gas diffuser is correct for the liner being used See table and dif
10. P372 Series Magnum 250C Wi P202 H 2 POWER MIG 200 LINCOLN 1 INSTALLATION A TECHNICAL SPECIFICATIONS POWER MIG 200 INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 150 Amp Rated Output Input Current 150 Amp Rated Output 208 230 50 60 Hz 28 26 Amps RATED OUTPUT Amps Volts at Rated Amperes 200 Amps 22 Volts 180 Amps 23 Volts 150 Amps 24 Volts OUTPUT Welding Current Range Maximum Open Circuit Voltage Welding Voltage Range 30 200 Amps 40 Volts 13 5 22 Volts RECOMMENDED INPUT WIRE AND FUSE SIZES 75 C Copper Wire 75 C Copper Wire Input Ampere in Conduit in Conduit Input Voltage Fuse or Breaker Rating On AWG IEC Sizes AWG IEC Sizes For lengths For lengths Frequency Hz Size Super Lag Nameplate up to 100 ft exceeding 100 ft 208 50 60 10 6 mm 8 10 mm 230 50 60 10 6 mm 8 10 mm NOTE Use 10 AWG Grounding Wire PHYSICAL DIMENSIONS Height Width Depth Weight 31 79 in 18 88 in 38 78 in 210 lbs 808 mm 480 mm 985 mm 95 kg WIRE SPEED RANGE Wire Speed 50 700 IPM 1 27 17 8 m minute POWER MIG 200 LINCOLN 5 iin INSTALLATION Read entire installation section before starting installation SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the POWER MIG 200 Operating Manual should install and operate
11. CABLE CLEANING To help prevent feeding problems clean cable liner after using approximately 300 pounds 136 kg of electrode Remove the cable from the wire feeder and lay it out straight on the floor Remove the con tact tip from the gun Using an air hose and only par tial pressure gently blow out the cable liner from the gas diffuser end POWER MIG 200 LINCOLN D 2 MAINTENANCE ES CAUTION Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out If this has been done and feed prob lems are experienced try liner replacement and refer to trouble shooting section on rough wire feeding LINER REMOVAL AND REPLACE MENT NOTE Changing the liner for a different wire size requires replacement of the gas diffuser per Table D 1 to properly secure the different liner TABLE D 1 Diameter of Electrodes Used 025 030 Steel 0 6 0 8 mm Replacement Liner Part Number M16087 2 Size Stencilled on End of Liner Bushing 030 0 8 mm Adjustable Nozzle Gas Diffuser Gas Diffuser Part No and Stencil and Stencil S19418 3 S19418 2 035 045 Stee 0 9 1 2 mm M16087 1 1045 1 2 mm S19418 3 S19418 1 3 64 Aluminum M17714 1 3 64 1 2 mm S19418 3 S19418 1 1 2 mm LINER REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR
12. POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION GAS FLOW PROBLEMS Gas does not flow when gun trigger 1 Make sure gas supply is con is pulled nected properly and turned on If the gas solenoid does actuate click when the gun trigger is If all recommended possible areas pulled there may be a restriction of misadjustment have been in the gas supply line checked and the problem persists Contact your local Lincoln The gun cable assembly may be Authorized Field Service Facility faulty Check or replace If gas solenoid does not operate when gun trigger is pulled the problem is within the POWER MIG 200 Make sure the gun is pushed all the way into gun mount and is properly seated CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed POWER MIG 200 LINCOLN E Jequunu epoo SAIN e 104 221m9 elql6elll si eui sjeued eunsoj oue euo uo y 14255 0002 01 QAN 000 1 P TOON 15 XO8NV39 THOLON NOILdO 10085 404 3000 WORLOSIBTVNOLVN OL anaodsNval Leg mg
13. checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed POWER MIG 200 LINCOLN E 3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS 1 Poor arc striking with electrode sticking or blasting off PROBLEMS SYMPTOMS 1 Rough wire feeding or wire will not feed but drive rolls are turn ing POSSIBLE AREAS OF MISADJUSTMENT OUTPUT PROBLEMS Make sure settings for wire feed speed and voltage are correct for process being used The gas shielding may be improper for process being used Check imput line voltage to be with in machines recommended rating range Check that the machine recon nect panel is configured properly for the applied voltage FEEDING PROBLEMS POSSIBLE AREAS OF USTMENT S The gun cable may be kinked or twisted The wire may be jammed in the gun cable or gun cable may be dirty Check drive roll tension and position of grooves Check for worn or loose drive rolls The electrode may be rusty or dirty Check for damaged or incorrect contact tip Check wire spindle for ease of rotation and adjust break ten sion knob if necessary
14. 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 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety nes minimize exposure to EMF fields from the welding circuit 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not at
15. fuser stencil 8 Tighten the set screw in the side of the gas diffuser against the cable liner using a 5 64 2 0 mm Allen wrench FIGURE D 1 SET SCREW BRASS CABLE CONNECTOR 31 8mm LINER SET A GAS NOZZLE INSULATOR IF USED 9 This screw should only be gently tightened Overtightening will split or collapse the liner and cause poor wire feeding GAS NOZZLE POWER MIG 200 LINCOLN de MAINTENANCE D 3 GUN HANDLE DISASSEMBLY TABLE D 2 3 SS ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS The internal parts of the gun handle may be FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES inspected or serviced if necessary English Metric Description Part No Size Size The gun handle consists of two halves that are CABLE LINER held together with a collar on each end To For 15 4 5 m or M16087 2 025 030 0 6 0 8 mm open up the handle turn the collars approxi shorter Cable M16087 1 035 045 0 9 1 2 mm M17714 1 3 64 1 2 mm mately 60 degrees counterclockwise the same direction as removing a right hand thread until the collar reaches a stop Then pull the collar CONTACT TIPS off the gun handle If the collars are difficult to Standard Duty S19391 6 025 0 6 mm Alum wire Alum wire turn position the gun handle against a corner 030 0 8 place Screwdriver against the tab on the col SR SEH BM lar and give the screwdriver a sharp blow to SE ges oe
16. in Figure have quali NATIONAL ELECTRICAL fied electrician connect a receptacle Customer CODE AND OR LOCAL Supplied or cable to the input power lines and the ie ee system ground per the U S National Electrical PROPER GROUNDING Code and any applicable local codes See Technical Specifications at the beginning of this chapter for proper wire sizes For long runs over PHASE SYSTEM OR TO ONE 100 feet larger copper wires should be used Fuse PHASE OF A TWO OR the two hot lines with super lag type fuses as THREE PHASE SYSTEM 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 OUTPUT POLARITY CONNECTIONS grounding of the welder frame when the welder CONNECT TO HOT WIRES OF A THREE WIRE SINGLE plug is inserted into a grounded receptacle The welder as shipped from the factory is connected for electrode positive polarity This is the normal FIGURE A 3 Receptacle Diagram polarity for GMA welding CONNECT TO A SYSTEM If negative polarity is required interchange the GROUNDING WIRE SEE THE connection of the two cables located in the wire drive UNITED STATES NATIONAL ELECTRICAL CODE AND OR compartment near the front panel The electrode LOCAL CODES FOR OTHER cable which is attached to the wire drive is to be con nected to the negative lab
17. on the inside of the wire compartment door Wire Speed Control This controls the wire feed speed from 50 700 inches per minute 1 2 17 8 m min Wire speed is not affected when changes are made in the voltage control WIRE DRIVE ROLL The drive rolls installed with the POWER MIG each have two grooves both for 030 035 0 8 0 9 mm solid steel electrode Drive roll size is indicated by the stenciling on the exposed side of the drive roll If feed ing problems occur then the drive roll may be reversed or changed See Procedure for Changing Drive Roll in this section WIRE SIZE CONVERSION PARTS The POWER MIG 200 is rated to feed 025 through 045 0 6 1 2 mm solid or cored electrode sizes The drive roll kits and Magnum 250L gun and cable parts are available to feed different sizes and types of electrodes See Accessories section POWER MIG 200 LINCOLN et OPERATION ES PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS Turn off the power source ech 2 Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine Lift the cast idle roll assembly and allow it to sit in an upright position 3 Remove the outside wire guide retaining plate by loosening the two large knurled screws 4 Twist the drive roll retaining mechanism to the unlocked position as shown below and remove the drive roll See Figure 4 FIGURE A 4 5 Remove the insi
18. the spool gun will increase or decrease the spool gun wire feed speed NOTE the wire feed speed control on the Power Mig Panel has no affect on the spool gun s wire feed speed 4 Refer to the procedure decal on the Power Mig for initial aluminum settings Make a test weld to deter mine the final settings 5 To return to normal POWER MIG 200 welding release the spool gun trigger set spool gun selector Switch to normal and reset feeder gun voltage pro cedure setting if necessary POWER MIG 200 LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill T e Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts GENERAL MAINTENANCE In extremely dusty locations dirt may clog the air pas sages causing the welder to run hot Blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on internal parts The fan motors have sealed ball bearings which require no service DRIVE ROLLS AND GUIDE PLATES After every coil of wire inspect the wire drive mecha nism Clean it as necessary by blowing with low pres sure compressed air Do not use solvents for cleaning the idle roll because it may wash the lubricant out of the bearing All drive rolls are stamped with the wire sizes they will feed I
19. this equipment Machine must be grounded per any nation al local or other applicable electrical codes The POWER MIG power switch is to be in the OFF position when installing work cable and gun and when connecting other equipment UNCRATING THE POWER MIG 200 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 pas sages and cause overheating A 2 INPUT POWER GROUNDING AND CONNECTION DIAGRAMS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring All input power must be electrically dis connected before proceeding 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 volt age amperes phase and frequency specified on the welder nameplate Also be sure the planned installation will meet the U S National Elec
20. 5 0 6 1 2 mm solid steel 035 0 9 mm stainless 3 64 1 2 mm alu minum and 045 1 2 mm Outershield as well as 035 0 9 mm and 045 1 2 mm Innershield self shielding electrodes The POWER MIG is factory equipped to feed 035 0 9 mm electrodes It also includes a 200A 6096 duty cycle or 250A 40 duty cycle rated 12 ft 3 6 m GMAW gun and cable assembly equipped for these wire sizes Use of GMAW processes requires a supply of shielding gas WELDING CAPABILITY The POWER MIG 200 is rated at 200 amps 22 volts at a 3096 duty cycle based on a ten minute cycle time It is capable of higher duty cycles at lower output currents The tapped transformer design makes it well suited for use with most portable or in plant gen erating systems LIMITATIONS The output voltage current of the POWER MIG 200 is subject to vary if the input power to the machine varies due to its tapped transformer power topology In some cases an adjustment of WFS preset and or voltage tap selection may be required to accommo date a significant drift in input power DESCRIPTION OF CONTROLS Power ON OFF Switch Place the lever in the ON position to energize the POWER MIG 200 Voltage Control Seven voltage tap selections are provided Labeled A minimum voltage through G maximum voltage It should only be adjusted when not welding The control selection can be preset to the setting specified on the Procedure Decal
21. AL CYLINDER MOUNTING KIT K1702 1 Permits stable side by side mounting of two full size 9 dia x 5 high gas cylinders with no lift loading Simple installation and easy instructions provided Includes upper and lower cylinder supports wheel axles and mounting hardware ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES The following Magnum 250L gun and cable assem blies are separately available for use with the POWER MIG 200 Each is rated 200 amps 60 duty cycle and is equipped with the integrated connector twist lock trigger connector fixed nozzle and insulator and includes a liner diffuser and contact tips for the wire sizes specified English Wire Metric Wire EM Part No Size Size 0 3 0 m 035 045 15 4 5 025 030 0 6 0 8 mm 10 8 0 15 45m MAGNUM GUN CONNECTION KIT Optional K466 6 Using the optional K466 6 Magnum Connection kit for the POWER MIG permits use of standard Magnum 200 300 or 400 gun and cable assemblies SPOOL GUN AND ADAPTER KIT K1809 1 The K1809 1includes the Magnum 250SG Spool gun and the adapter kit for connecting the spool gun to the Power MIG 200 The Adapter Kit provides toggle switch selection between the machine s use with its feeder gun or the spool gun for same polarity welding with different wire and gas processes The kit includes a spool gun adapter module assem bly with a single connecting plug and trigg
22. Heavy Duty 19392 1 035 0 9 mm turn the collar past an internal locking rib 19292 2 045 oe Tapered 19393 5 025 0 6 mm S19393 6 030 0 8 519393 1 035 0 9 519393 2 045 1 2 Tab For Aluminum S18697 46 3 64 1 2 mm Alum Wire Alum Wire GAS NOZZLES Counterclockwise Fixed Flush M16081 1 3 8 9 5 mm M16081 2 1 2 12 7 mm M16081 3 5 8 15 9 mm Recessed M16080 1 3 8 9 5 mm M16080 2 1 2 12 7 mm M16080 3 5 8 15 9 mm Requires Gas Diffuser As bly S19418 3 025 045 0 6 1 2 mm Adjustable Slip On M16093 2 1 2 12 7 mm M16093 1 5 8 15 9 mm Requires Nozzle Insulator S19417 1 As bly Requires Gas Diffuser S19418 2 025 030 As bly S19418 1 035 045 Gasless Nozzle M16938 For Innershield GUN TUBE ASSEMBLIES Standard 60 18920 45 S19890 Included with POWER MIG 200 Requires 519418 1 Gas Diffuser Assembly POWER MIG 200 LINCOLN 1 TROUBLESHOOTING ES HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you
23. IM693 POWER MIG 200 vom For use with machine Code Numbers 10564 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 thought ful 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 Date of Purchase Serial Number Code Number Model Where Purchased OPERATOR S MANUAL ge gt MR pm ISO 9001 Designed and Under a Quality d by ABS Quali to ISO 9001 CERTIFICATE NUMI LI NCOLN Copyright 2001 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above Fo
24. M A New Approach to Industrial Economics 5 00 NA The American Century of John C Lincoln Name Address Telephone Signature as it appears on Charge Card Price Code Quantity Cost 0 t 100 PH i AH WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra ELE LATE e E GUB MU GH Oa CRM EER e Xe uc a Sal e sis HIE Weal AMI W o Qi el all oa Y O el ai ay d o lala AA ll Ja dan Y Jio moe Keep flamm
25. able materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e naedoe6 0o08 CIE REA 0 7 5 eis A d s Jo ALD al gll pis Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo A HAUSHERMRELTTF ez 119 59 s ESSAI dise ule lag al ad ne Al aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep yo
26. ad 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 Also see item 1 b Mar 95 POWER MIG 200 LINCOLN amp SAFETY WELDING SPARKS gt 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 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 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 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 purcha
27. alled between the regulator and cylinder valve adapter is equipped with a plastic washer be sure itis seated for connection to the CO cylinder 5 Attach one end of the inlet gas hose to the outlet fitting of the flow regulator the other end to the POWER MIG 200 rear fitting and tighten the union nuts securely with a wrench 6 Before opening the cylinder valve turn the regula tor adjusting knob counterclockwise until the adjusting spring pressure is released 7 Standing to one side open the cylinder valve slow ly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully WARNING Never stand directly in front of or behind the flow regulator when opening the cylinder valve Always stand to one side 8 The flow regulator is adjustable Adjust it to the flow rate recommended for the procedure and process being used before making the weld POWER MIG 200 LINCOLN P OPERATION 1 Read entire Operation section before operating the POWER MIG 200 WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground A 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
28. and that of your helpers from the arc rays 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 23 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 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 prod ucts 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 Re
29. and thick ness and gas for GMAW being used Use the Application Chart on the door inside the wire com partment as a quick reference for some common welding procedures 3 Press the trigger to feed the wire electrode through the gun and cable and then cut the electrode within approximately 3 8 10 mm of the end of the con tact tip 3 4 20 mm Outershield 4 f welding gas is to be used turn on the gas supply and set the required flow rate typically 25 35 CFH 12 16 liters min 5 When using Innershield electrode the gas nozzle may be removed from the insulation on the end of the gun and replaced with the gasless nozzle This will give improved visibility and eliminate the possi bility of the gas nozzle overheating 6 Connect work cable to metal to be welded Work clamp must make good electrical contact to the work The work must also be grounded as stated in Arc Welding Safety Precautions WARNING When using an open arc process it is necessary to use correct eye head and body protection 7 Position electrode over joint End of electrode may be lightly touching the work 8 Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to work distance is about 3 8 10 mm 3 4 20 mm for Outershield 9 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out 10 When no more welding is to be done close valve on g
30. as cylinder if used momentarily operate gun trigger to release gas pressure and turn off POWER MIG 200 POWER MIG 200 LINCOLN 5 5 OPERATION B 5 AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures 1 Do not kink or pull cable around sharp corners 2 Keep the gun cable as straight as possible when welding or loading electrode through cable 3 Do not allow dolly wheels or trucks to run over cables 4 Keep cable clean by following maintenance instructions 5 Use only clean rust free electrode The Lincoln electrodes have proper surface lubrication 6 Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed 7 Keep wire reel spindle brake tension to minimum required to prevent excess reel over travel which may cause wire loop offs from coil 8 Use proper drive rolls and wire drive idle roll pres sure for wire size and type being used FAN CONTROL The fan is designed to come on when input power is applied to the POWER MIG 200 and go off when power is removed INPUT LINE VOLTAGE VARIATIONS High Line Voltage Higher than rated input voltage will result in output voltages higher than normal for a given tap setting If your input line is high you may want to select a lower voltage tap than given on the recommended procedure chart Low Line Voltage You may not be able to get maximu
31. ct 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock 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 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin
32. de wire guide plate 6 Replace the drive and idle rolls and inside wire guide with a set marked for the new wire size NOTE Be sure that the gun liner and contact tip are also sized to match the selected wire size 7 Manually feed the wire from the wire reel over the drive roll groove and through the wire guide and then into the brass bushing of the gun and cable assembly 8 Replace the outside wire guide retaining plate by tightening the two large knurled screws Reposition the adjustable pressure arm to its original position to apply pressure Adjust pressure as necessary WIRE REEL LOADING READI REELS SPOOLS OR COILS To Mount a 30 Lb 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter Open the Wire Drive Compartment Door Depress the Release Bar on the Retaining Collar and remove it from the spindle Place the Optional Adapter on the spindle gt Re install the Retaining Collar Make sure that the Release Bar pops and that the collar retainers fully engage the retaining ring groove on the spindle 5 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position POWER MIG 200 6 Position the Readi Reel so that it will rotate in a direction when feed ing so as to be de reeled from top of the coil Set one of the Readi Reel inside wires on the slot in the retain ing spring tab 8 Lower the Read
33. eled terminal and the work lead which is attached to the work clamp is to CONNECT TO HOT WIRES be connected to the positive labeled terminal THREE WIRE SINGLE PHASE SYSTEM OR TO ONE PHASE OF TWO OR THREE PHASE SYSTEM POWER MIG 200 LINCOLN net INSTALLATION 4 GUN AND CABLE INSTALLATION The Magnum 250L gun and cable provided with the POWER MIG 200 is factory installed with a liner for 035 045 0 9 1 2 mm electrode and an 035 0 9 mm contact tip Be sure that the contact tip liner and drive rolls all match the size of the wire being used WARNING Turn the welder power switch off before installing gun and cable 1 Lay the cable out straight 2 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 3 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 4 Connect the gun trigger connector from the gun and cable to the mating receptacle inside the com partment located above the gun connection made in item 3 above Make sure that the keyways 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 Arg
34. er switch a rear gas inlet fitting hose solenoid valve assembly and mounting hardware with installation and operation instructions WARNING Remove all input power to the POWER MIG 200 before installing the Spool Gun and Kit POWER MIG 200 LINCOLN C2 ACCESSORIES MAKING A WELD WITH THE SPOOL GUN ADAPTER KIT AND SPOOL GUN INSTALLED CAUTION In either toggle switch position closing either gun trigger will cause the electrode of both guns to be electrically HOT Be sure unused gun is posi tioned so electrode or tip will not contact metal case or other metal common to work 1 Setting spool gun selector switch to the Normal position and pulling the trigger for the built in feed er gun e Disables spool gun operation and spool gun gas solenoid valve Closing feeder gun trigger starts feeder gun welding and makes both electrodes electrically HOT 2 Setting spool gun selector switch to the Spool Gun Position and pulling SPOOL GUN Trigger e Disables built in feeder gun operation and machine gas solenoid valve Enables spool gun operation and spool gun gas solenoid valve e Closing spool gun trigger starts spool gun weld ing and makes both electrodes electrically 3 Operation with POWER MIG 200 Turn the POWER MIG 200 input power ON Adjusting the voltage tap control will increase or decrease your welding voltage e Adjusting the wire speed control on
35. f a wire size other than that stamped on the roll is used the drive roll must be changed For instructions on replacing or changing drive roll see Wire Drive Rolls in Operation section CONTACT TIP AND GAS NOZZLE INSTALLATION 1 Choose the correct size contact tip for the elec trode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser 2 Screw the appropriate fixed gas nozzle fully onto the diffuser Either the standard 50 12 7 mm flush nozzle or other optional flush or recessed spray arc nozzle sizes may be used See Table D 2 in this section 3 If using optional adjustable slip on nozzles see Table D 2 in this section Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser e Slip the appropriate gas nozzle onto the nozzle insulator Either a standard 50 12 7 mm or optional 62 15 9 mm I D slip on gas nozzle may be used and should be selected based on the welding application Adjust the gas nozzle as appropriate for the GMAW process to be used Typically the con tact tip end should be flush to 12 3 2 mm extended for the short circuiting transfer process and 12 3 2 mm recessed for spray transfer GUN TUBES AND NOZZLES 1 Replace worn contact tips as required 2 Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required GUN
36. he gun and cable assembly without restriction Reposition the adjustable pressure arm to its origi nal position to apply pressure to the wire 4 Press gun trigger to feed the electrode wire through the gun IDLE ROLL PRESSURE SETTING The optimum idle roll pressure varies with type of wire wire diameter surface conditions lubrication and hardness As a general rule hard wires may require greater pressure and soft or aluminum wire may require less pressure than the factory setting The optimum idle roll setting can be determined as follows 1 Press end of gun against a solid object that is elec trically isolated from the welder output and press the gun trigger for several seconds 2 If the wire birdnests jams or breaks at the drive roll the idle roll pressure is too great Back the adjustment knob out 1 2 turn run new wire through gun and repeat above steps 3 If the only result was drive roll slippage loosen the adjustment knob on the conductor plate and pull the gun cable forward about 6 15 cm There should be a slight waviness in the expose wire If there is not waviness the pressure is too low Tighten the adjustment knob 1 4 turn reinstall the gun cable and repeat the above steps MAKING A WELD 1 Check that the electrode polarity is correct for the process being used then turn the power switch ON 2 Set desired arc voltage tap and wire speed for the particular electrode wire material type
37. i Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 9 Slide cage all the way onto the adapter until the retaining spring pops up fully CAUTION CHECK TO BE SURE THE RETAINING SPRING HAS FULLY RETURNED TO THE LOCKING POSITION AND HAS SECURELY LOCKED THE READI REEL CAGE IN PLACE RETAINING SPRING MUST REST ON THE CAGE NOT THE WELDING ELECTRODE 10 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle FIGURE B 1 2 IN OD SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR a d INSIDE CAGE WIRES RELEASE BAR To Mount 10 to 44 Lb 4 5 20 kg Spools peas mm Diameter or 14Lb 6 Kg Innershield Coils GROOVES READI REEL For 13 14 Ib 6 Kg Innershield coils a K435 Coil Adapter must be used 1 Open the Wire Drive Compartment Door 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 3 Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the back side of the spool Note an arrow mark on the spindle lines up with the brake holding pin to assist in lining up a hole Be certain the wire comes off the reel in a direction so as to de reel from the top of the coil 4 Re install the Retaining Collar Make sure that the Release Bar
38. 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 SYMP TOMS 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 possibilities 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 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER MIG 200 LINCOLN B E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS Major Physical or Electrical Damage is Evident There is no wire feed or open cir cuit voltage when the gun trigger is pulled Input power is applied to POWER MIG 200 Output voltage and wire feed is pre sent when gu
39. m output from the machine if the line voltage is less than rated input The unit will continue to weld but the output may be less than normal for a given tap setting If your input line is low you may want to select a higher voltage tap than given on the recom mended procedure chart WIRE FEED OVERLOAD PROTECTION The POWER MIG has solid state overload protection of the wire drive motor If the motor becomes over loaded the protection circuitry turns off the wire feed speed and gas solenoid Check for proper size tip liner and drive rolls for any obstructions or bends in the gun cable and any other factors that would impede the wire feeding to resume welding simply pull the trigger There is no circuit breaker to reset as the protection is done with reliable solid state elec tronics WELDING THERMAL OVERLOAD PROTECTION The POWER MIG 200 has built in protective ther mostats that respond to excessive temperature They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating tem perature because of a frequent overload or high ambient temperature plus overload The thermostats automatically reset when the temperature reaches a safe operating level and welding and feeding are allowed again when gun is retriggered Steel Thickness Wire Feed Speed Voltage Tap Wire Dia Gas Type WireType Polarity 18 gage 16 gagd14 gage 12 3 16 5 16 1 2 Outershield 3 4 ESOt
40. n trigger is not pulled not activated Machine output is low Welds are cold weld bead is rounded or bumped up demonstrating poor wetting into plate POSSIBLE AREAS OF MISADJUSTMENT OUTPUT PROBLEMS 1 Contact your Local Lincoln Authorized Field Service Facility 1 The gun trigger or cable may be faulty Check or replace gun assembly 2 The thermal protection circuit may be activated If this is the case allowing the machine to cool will clear the error condition 3 Make sure input voltage is cor rect and matches nameplate rat ing and reconnect panel configu ration 4 If spool gun option kit is in stalled check to see that it is set to Normal if pulling the gun trig ger associated with built in feed er and Spool Gun if pulling spool gun trigger 1 Remove gun assembly from machine If problem is solved gun assembly is faulty Repair or replace 2 If problem persists when gun assembly is removed from machine then the problem is within the POWER MIG 200 1 Check input voltage Make sure input voltage matches name plate rating and reconnect panel configuration 2 Make sure settings for wire feed speed and voltage are correct for process being used 3 Make sure output polarity is cor rect for process being used 4 Check welding cables and gun assembly for loose or faulty con nections RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been
41. nsion vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie Bons LES MACHINES SOUDER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants
42. on blend gas and an inlet gas hose are factory provided with the POWER MIG 200 When using 100 CO an additional adapter will be required to connect the regulator to the gas bottle WARNING CYLINDER may explode if damaged Gas under pressure is explosive Always keep gas cylinders in an upright position and always keep chained to undercarriage or stationary support See American National Standard Z 49 1 Safety in Welding and Cutting published by the American Welding Society Install shielding gas supply as follows 1 Set gas cylinder on rear platform of POWER MIG 200 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 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 10096 CO cylinder an additional regulator adapter must be inst
43. pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la te
44. r Diesel Engines The Above For Gasoline 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 amp 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 AN FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS may be dangerous 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
45. se Hecommended 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 CYLINDER may explode if damaged 7 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 B Always keep cylinders in an upright position securely chained to an undercarriage or fixed support O
46. t leur place POWER MIG 200 LINCOLN V V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above 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 A 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 injur
47. tempt to override the idler by pushing on the throttle control rods while the engine is running 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 X Connect the work cable to the workpiece as close as possible to the area being welded 1 9 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 Do not work next to welding power source Mar 95 POWER MIG 200 LINCOLN 8 SAFETY 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 conta
48. that request UPS shipment please add 5 00 For order value up to 49 99 10 00 15 00 For North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders CHECKONE Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only Credit Card account No 11044 Ep bate H LL Les THIS FORM TO ORDER Books OR FREE INFORMATIVE CATALOGS Welding School Titles 80 New Lessons in Arc Welding Seminar Information ED 45 How to Read Shop Drawings Educational Video Information ED 93 luames F Lincoln Arc Welding Foundation Book Information Welding Preheat Calculator 300 wC8 JFLF 515 Pipe Welding Charts 450 2089 SUBTOTAL __ Additional Shipping Costs ifany _ TOTALCOST For order value between 50 00 amp 99 99 For order value between 100 00 amp 149 00 Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Procedure Handbook Twelfth Edition Incentive Management 5 00 I
49. tion enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com 05 paineis abertos ou guardas removidas OSILDI RALE CHkBEELZVCNEUS CHRRIARRARS 20 Sel AE sz HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O Chinese Qai oe Jung dul ale f ARA bi jua e Qui BALL cal z ue Aie Ab pha NM ale cuts UI ai l y e Aale Viel Al all LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBUOX HD OHBRBEE lt K RA ETISRIUCESU CL TRHORERMEI HS 0 SAAD HA zeit ele BEHE ET Aal veel d illai aui y Qui AAL ell oig Gail guet agily Ca LINCOLN 5 e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
50. trical 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 Models that have multiple input voltages specified on the nameplate e g 208 230 are shipped con nected for the highest voltage If the welder is to be operated on lower voltage it must be reconnected according to the instructions in Figure A 1 for dual voltage machines and Figure A 2 for triple voltage machines WARNING Make certain that the input power is electrically disconnected before removing the screw on the reconnect panel access cover POWER MIG 200 LINCOLN INSTALLATION nm FIGURE A 1 Dual Voltage Machine Input Connections INPUT SUPPLY CONNECTION DIAGRAM SINGLE PHASE WARNING desired voltage 50 60 HZ Disconnect input power before inspecting or servicing machine Do not operate with covers removed ELECTRIC SHOCK CAN KILL Only qualified persons should install Do not touch electrically live parts use or service this equipment Install and Ground machine National Electrical Code and local codes Use Grounding Stud or Lug inside 230 V 208 V Use CU wire only Consult Instruction Manual before installing or operating shipped with a 7 ft input cable and plug connected to the welder CONNECT TO SYSTEM GROUNDING WIRE SEE THE UNITED STATES 4 Using the instructions
51. ur head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de 105 humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria 9 fsUPBHEILTASESUCFEU CARE EUR Ea fE za 24752 else SUAS MAS sis PARAH 7 Turn power off before servicing Desconectar el cable de ali mentaci n de poder la antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas AVFFVA F EAZLRUP PSB ET BRAY FE e HE BIS AGS XA Do not operate with panel open guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protec
52. vered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding 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 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 For details write and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location lOrders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only I IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders
53. y damage to this equipment MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Section Technical Specifications pto paca alertes A 1 Safety e A 2 Uncrating the POWER MIG 200 se A 2 WEE 2 Input Power Grounding and connection Diagrams A 2 thru A 3 Output Polarity Connections sis A 3 Gun and Cable Installation EE 4 Shieldilitj SS A 4 EIDEN ee Section B Safety Precautions ardt nee an aire B 1 PLOGUCHD CSCrIPUOM MEE Em B 2 Recommended Processes and Equipment ppp B 2 Welding Capability 2 Bin Ce EE B 2 Desceriptionrof Controls B 2 Wire Drive Ke cm B 2 Wire Size Conversion parts us B 2 Procedure for Changing Drive Roll B 3 Wire Rene cases i demere d B 3 Mounting of 10 to 30 165 Spools B 3 To Start the Weider B 3 F eding B 4 Idle Roll Pressure Setting us B 4 Making a Wold Em B 4 Avoiding Wire Feeding Problems AA B 5 RE 5 Input Line Voltage PrGtectliG EEN B 5 Wire Feed overload Protection eet Leer ieee B 5 Welding Thermal Overload B 5 ee Section C Drive
54. ylinders should be located e Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment CGA publication P l Precautions for Safe Handling of Compressed Gases in Oylinders 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 POWER MIG 200 LINCOLN 5 M SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions 6 et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les
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