Lincoln MIG 215 User Manual

POWER MIG ®215

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SVM167-A

January, 2011

For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.

11070, 11099, 11247

View Safety Info View Safety Info View Safety Info View Safety Info

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

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

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.

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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.

POWER MIG® 215

ii ii

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 contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding 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 within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven­tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre­cautions are also required when welding on galvanized
steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

vapors

to

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5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

POWER MIG® 215

iii iii

SAFETY

WELDING and CUTTING
SPARKS can cause fire or
explosion.

6.a.
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.

6.h. Also see item 1.c.

Remove fire hazards from the welding area.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders

If

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.

containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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POWER MIG® 215

iv iv

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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a. Utiliser un bon masque avec un verre filtrant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du rayon­nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

POWER MIG® 215

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

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Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv

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

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

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

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

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P487 Series &

P202-H.2

vv

POWER MIG® 215

TABLE OF CONTENTS

- INSTALLATION SECTION -

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

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Uncrating the POWER MIG® 215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

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

Output Polarity Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Gun and Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Section ASection A

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POWER MIG® 215

INSTALLATION

TECHNICAL SPECIFICATIONS – POWER MIG® 215

INPUT – SINGLE PHASE ONLY

A-2A-2

Standard Voltage/Phase/Frequency

208/230/1/50/60 Hz

Input Current @ 170 Amp Rated Output Input Current @ 215 Amp Rated Output

(With 115V receptacle loaded to 15A) (With 115V receptacle loaded to 15A)

39/35 Amps 45/41 Amps

RATED OUTPUT

Duty Cycle Amps Volts at Rated Amperes

30% 215 Amps 22 Volts
40% 190 Amps 23 Volts
60% 170 Amps 24 Volts

OUTPUT

Welding Current Range Maximum Open Circuit Voltage Welding Voltage Range

30 – 250Amps 35 Volts 13.5-24 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 60 45A 10 (6 mm2) 8 (10 mm2)
230/50/60 60 41A 10 (6 mm2) 8 (10 mm2)

NOTE: Use #10 AWG Grounding Wire

WIRE SPEED RANGE

Wire Speed 50 – 700 IPM (1.27 – 17.8 m/minute)

PHYSICAL DIMENSIONS

Height Width Depth Weight

31.79 in 18.88 in 38.78 in 210 Ibs
808 mm 480 mm 985 mm 95 kg

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

-4°F to 104°F(-20°C to +40°C)

STORAGE TEMPERATURE RANGE

-40°F to 185°F(-40°C to +40°C)

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POWER MIG® 215

A-3

INSTALLATION

A-3

Read entire installation section before starting
installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform
this installation.

• Only personnel that have read and under­stood the POWER MIG® 215 Operating
Manual should install and operate this
equipment.

• Machine must be grounded per any
national, 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® 215

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.

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 dis­connected 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 volt­age, amperes, phase, and frequency specified on
the welder nameplate. Also be sure the planned
installation will meet the U.S. National Electrical
Code and local code requirements. This welder may
be operated from a single phase line or from one
phase of a two or three phase line.

2. Models that have multiple input voltages specified
on the nameplate (e.g. 208/230) are shipped con­nected 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.

LOCATION

Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
out the front. A location that minimizes the amount of
smoke and dirt drawn into the rear louvers reduces the
chance of dirt accumulation that can block air pas­sages and cause overheating.

WARNING

Make certain that the input power is electrically
disconnected before removing the screw on the
reconnect panel access cover.

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POWER MIG® 215

A-4

INSTALLATION

FIGURE A.1 — Dual Voltage Machine Input Connections

A-4

3. The 208/230 volt 50/60 Hz model POWER MIG® is
shipped with a 7 ft.(2.1m). input cable and plug con­nected to the welder.

4. Using the instructions in Figure A.2, have a qualified
electrician connect a receptacle (Customer
Supplied) or cable to the input power lines and the
system ground per the U.S. National Electrical Code
and any applicable local codes. See “Technical
Specifications” at the beginning of this chapter for
proper wire sizes. For long runs over 100 feet, larg­er copper wires should be used. Fuse the two hot
lines with super lag type fuses as shown in the fol­lowing diagram. The center contact in the receptacle
is for the grounding connection. A green wire in the
input cable connects this contact to the frame of the
welder. This ensures proper grounding of the welder
frame when the welder plug is inserted into a
grounded receptacle.

FIGURE A.2 — Receptacle Diagram

CONNECT TO A SYSTEM
GROUNDING WIRE. SEE
THE UNITED STATES
NATIONAL ELECTRICAL
CODE AND/OR LOCAL
CODES FOR OTHER
DETAILS AND MEANS FOR
PROPER GROUNDING.

OUTPUT POLARITY CONNECTIONS

The welder, as shipped from the factory, is connected
for electrode positive (+) polarity. This is the normal
polarity for GMA welding.

If negative (–) polarity is required, interchange the con­nection of the two cables located in the wire drive com­partment near the front panel. The electrode cable,
which is attached to the wire drive, is to be connected
to the negative (–) labeled terminal and the work lead,
which is attached to the work clamp, is to be connect­ed to the positive (+) labeled terminal.

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CONNECT TO HOT WIRES
OF A THREE-WIRE, SINGLE
PHASE SYSTEM.

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POWER MIG® 215

A-5

INSTALLATION

GUN AND CABLE INSTALLATION

The Magnum 250L gun and cable provided with the
POWER MIG® 215 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

A-5

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.

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 Gun
Adapter 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 compart­ment 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 Argon blend gas, and an inlet
gas hose are factory provided with the POWER MIG®

215. When using 100% CO2an additional adapter will

be required to connect the regulator to the gas bottle.

3. Stand to one side away from the outlet and open
the cylinder valve for an instant. This blows away
any dust or dirt which may have accumulated in the
valve outlet.

WARNING

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

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

NOTE: If connecting to 100% CO2cylinder, an

additional regulator adapter must be
installed between the regulator and cylin­der valve. If adapter is equipped with a plas­tic washer, be sure it is seated for connec­tion to the CO2cylinder.

5. Attach one end of the inlet gas hose to the outlet fit­ting of the flow regulator, the other end to the
POWER MIG® 215 rear fitting, and tighten the
union nuts securely with a wrench.

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

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

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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®

215. Hook chain in place to secure cylinder to rear
of welder.

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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.

AUXILIARY POWER RECEPTACLES

(15 Amp 120 Volt Receptacle) The receptacles are UL
and CSA approved.

POWER MIG® 215

NOTES

A-6A-6

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POWER MIG® 215

TABLE OF CONTENTS

- OPERATION SECTION -

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

Safety Precautions ................................................................................................B-2

Product Description ...............................................................................................B-3

Recommended Processes and Equipment ...........................................................B-3

Welding Capability.................................................................................................B-3

Limitations..............................................................................................................B-3

Description of Controls ..........................................................................................B-3

Wire Drive Roll.......................................................................................................B-3

Wire Size Conversion parts...................................................................................B-3

Procedure for Changing Drive Roll........................................................................B-4

Wire Reel Loading .................................................................................................B-4

Mounting of 10 to 44 lbs. Spools...........................................................................B-4

To Start the Welder................................................................................................B-4

Feeding Electrode .................................................................................................B-5

Idle Roll Pressure Setting......................................................................................B-5

Wire Drive Configuration .......................................................................................B-5

Making a Weld.......................................................................................................B-6

Avoiding Wire Feeding Problems ..........................................................................B-7

Fan Control............................................................................................................B-7

Input Line Voltage Protection ................................................................................B-7

Wire Feed Overload Protection .............................................................................B-7

Welding Thermal Overload Protection...................................................................B-7

Section BSection B

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POWER MIG® 215

OPERATION

Read entire Operation section before
operating the POWER MIG® 215.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts
or electrode with skin or wet cloth­ing. Insulate yourself from work
and ground.

• Always wear dry insulating
gloves.

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

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

B-2B-2

WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

• Do not weld on closed containers.

ARC RAYS can burn eyes and
skin.

• Wear eye, ear and body protec­tion.

Observe all safety information throughout
this manual.

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POWER MIG® 215

B-3 B-3

33

22

11

OPERATION

PRODUCT DESCRIPTION

The POWER MIG® 215 is a complete semiautomatic
DC voltage arc welding machine built to meet NEMA
specifications. It combines a tapped transformer volt­age 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 15 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 feed­ing with standard built in feeder are also available.

LIMITATIONS

The output voltage/current of the POWER MIG® 215 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 accommodate a signifi­cant drift in input power.

DESCRIPTION OF CONTROLS

See Figure B.1

1. Power ON/OFF Switch — Place the lever in the

"ON" position to energize the POWER MIG® 215.

2. 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 on the inside of the wire compartment
door.

3. 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.

FIGURE B.1

RECOMMENDED PROCESSES AND
EQUIPMENT

The POWER MIG® 215 is recommended for GMA
welding processes using 10 to 44 lb (4.5 to 20 kg) 2"
(51 mm) I.D. spools or Readi-Reel®coils (with option­al adapter) of .025" through .045" (0.6 – 1.2 mm) solid
steel, .035" (0.9 mm) stainless, 3/64" (1.2 mm) alu­minum and .035 (0.9 mm), .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, 60% duty
cycle (or 250A, 40% duty cycle) rated, 15 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® 215 is rated at 215 amps @ 22
volts, at a 30% 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 generating
systems.

WIRE DRIVE ROLL

The drive rolls installed with the POWER MIG® have
two grooves one for .035(0.9mm) wire and the other for
.045(1.2mm) wire. Drive roll size is indicated by the
stenciling on the exposed side of the drive roll.

WIRE SIZE CONVERSION PARTS

The POWER MIG® 215 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.

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POWER MIG® 215

OPERATION

LOCKED POSITION

UNLOCKED POSITION

PROCEDURE FOR CHANGING
DRIVE AND IDLE ROLL SETS

1. Turn off the power source.

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 rolls. (See Figure B.2)

FIGURE B.2

B-4B-4

6. Position the Readi-Reel so that it will rotate in a direction
when feeding so as to be de- reeled from top of the coil.

7. Set one of the Readi-Reel inside cage wires on the slot
in the retaining spring tab.

8. Lower the Readi-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.

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5. Remove the inside wire guide plate.

6. Replace the drive 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:)

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 Optional Adapter on the spindle

4. Re-install the Retaining Collar. Make sure that the

Release Bar “pops up” 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

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at the 12 o'clock position.

To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300 mm
Diameter) or 14Lb.(6 Kg) Innershield Coils:

(For 13-14 lb. (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

3. Place the spool on the spindle making certain the spindle

4. Re-install the Retaining Collar. Make sure that the

TO START THE WELDER

Turn the “Power Switch” switch to “ON”. With the desired voltage
and wire speed selected, operate the gun trigger for welder output
and to energize the wire feed motor.

POWER MIG®

FIGURE B.1

remove it from 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 de­reel from the top of the coil.

Release Bar “pops up” and that the collar retainers fully
engage the retaining ring groove on the spindle.

OPERATION

ALUMINUM

OU TE R S H I EL D

METAL SHIE LD
INNERSHIELD

STEEL

STAI NLE SS

C O R E D W I R E S

SOLID WIR ES

6

1
3

2

5

4

B-5B-5

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FEEDING WIRE ELECTRODE

WARNING

When triggering, the electrode and
drive mechanism 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 or 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
the gun and cable assembly without restriction.
Reposition the adjustable pressure arm to its origi­nal position to apply pressure to the wire.

4. Press gun trigger to feed the electrode wire through

the gun.

IDLE ROLL PRESSURE SETTING

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the weld­ing power source before installation or
changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground
and could remain energized several seconds
after the gun trigger is released.

• Only qualified personnel should perform mainte­nance work.

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

POWER MIG® 215

The pressure arm controls the amount of force the drive
rolls exert on the wire. Proper adjustment of both pres­sure arm gives the best welding performance. For best
results, set both pressure arms to the same value.

Set the pressure arm as follows (See Figure B.2a):

Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6

Figure B.2a

WIRE DRIVE CONFIGURATION

(See Figure B.2b)

Changing the Gun Receiver Bushing

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the weld­ing power source before installation or
changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground
and could remain energized several seconds
after the gun trigger is released.

• Only qualified personnel should perform mainte­nance work.

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

Tools required:

• 1/4" hex key wrench.

NOTE: Some gun bushings do not require the use

of the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

OPERATION

GUN RECEIVER BUSHING

THUMB SCREW

OUTER WIRE GUIDE

SOCKET HEAD
CAP SCREW

CONNECTOR BLOCK

B-6B-6

5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.

Important: Do not attempt to completely

remove the socket head cap screw.

6. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the pre­cision fit, light tapping may be required to remove
the gun bushing.

7. Disconnect the shielding gas hose from the gun
bushing, if required.

8. Connect the shielding gas hose to the new gun
bushing, if required.

9. Rotate the gun bushing until the thumb screw hole
aligns with the thumb screw hole in the feed plate.
Slide the gun receiver bushing into the wire drive
and verify the thumb screw holes are aligned.

10. Tighten the socket head cap screw.

11. Insert the welding gun into the gun bushing and
tighten the thumb screw.

MAKING A WELD

1. Check that the electrode polarity is correct for the

process being used, then turn the power switch
ON.

3. Press the trigger to feed the wire electrode through
the gun and cable. For solid wire cut the electrode
within approximately 3/8" (10 mm) of the end of the
contact tip [3/4" (20 mm) for Outershield®].

4. When welding with gas, turn on the gas supply and
set the required flow rate (typically 25-35 CFH; 12­16 liters/min).

5. 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.

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

6. Position electrode over joint. End of electrode may
be lightly touching the work.

7. 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®].

2. Set desired arc voltage tap and wire speed for the
particular electrode wire, material type and thick­ness, and gas (for MIG and Outershield®) being
used. Use the Application Chart on the door inside
the wire compartment as a quick reference for
some common welding procedures.

Figure B.2b

8. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.

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POWER MIG® 215

OPERATION

B-7B-7

9. When no more welding is to be done, close valve
on gas cylinder (if used), momentarily operate gun
trigger to release gas pressure, and turn off
POWER MIG® 215.

NOTE: 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 possibility of the gas nozzle
overheating.

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 instruc-

tions.

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® 215 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 max­imum 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 recommended proce­dure chart.

WIRE FEED OVERLOAD
PROTECTION

The POWER MIG® has solid state overload protection
of the wire drive motor. If the motor becomes over­loaded, 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 electronics.

WELDING THERMAL OVERLOAD
PROTECTION

The POWER MIG® 215 has built-in protective ther­mostats that respond to excessive temperature. They
open the wire feed and welder output circuits if the
machine exceeds the maximum safe operating tem­perature 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.

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PROCEDURE CHART

Wire Feed Speed/Voltage Tap Settings

Wire Dia. Gas Type Wire Type

Outershield

.035 75Ar/25CO2OS71M DC+

.035 100%CO2OS71M DC+

.045 75Ar/25CO2OS71M DC+

Innershield

.035 NoneReq’d NR-211MP DC­.045 NoneReq’d NR-211MP DC­.045 NoneReq’d NR212 DC-

†

Contact Tip to Work Distance
* Note- Requires Multiple Pass
**.035 & .045 NR-211 MP are only recommended for a maximum steel thickness of 5/16"

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1" CTWD

5/8" CTWD

†

†

Polarity 18 gage 16 gage14 gage 12 gage10gage 3/16 1/4 5/16 3/8 1/2

50/B 70/B 80/B 90/C 100/C

40/B 50/B 60/B 65/C 70/C 90/C 110/D

POWER MIG® 215

250/D 300/E 350/F 500/G *500/G

300/E 350/F 500/G

200/E 225/F 250/G 250/G *250/G

50/B 70/C 90/C 110/D

**130/E

*130/E *150/E *150/E

NOTES

B-8B-8

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POWER MIG® 215

TABLE OF CONTENTS

- ACCESSORIES SECTION -

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

Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

3/64” (1.2mm) Aluminum Feeding Kit (K1703-1) . . . . . . . . . . . . . . . . . . . C-2

Readi-Reel Adapter (K363P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Dual Cylinder Mounting Kit (K1702-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Small Spool Spindle Adapter (K468) . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Alternative Magnum GMAW Gun and Cable Assemblies . . . . . . . . . . . . C-2

Magnum Gun Connection Kit (K466-6) . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Spool Gun and Adapter Kit (K1809-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Making a Weld (with the Spool Gun Adapter Kit) . . . . . . . . . . . . . . . . . . . C-3

Section CSection C

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POWER MIG® 215

ACCESSORIES

C-2C-2

DRIVE ROLL KITS

Refer to Table C.1 for various drive roll kits that are
available for the POWER MIG® 215.The item in Bold
is supplied standard with the POWER MIG® 215.

Wire Size Drive Roll Kit

Solid
Steel

Cored

Aluminum

.023”-.030” (0.6-0.8 mm)

.035” (0.9 mm) KP1696-035S

.045” (1.2 mm) KP1696-045S

.035” (0.9 mm) KP1697-035C
.045” (1.2 mm) KP1697-045C

3/64” (1.2 mm) KP1695-3/64A

TABLE C.1

KP1696-030S

3/64" (1.2 mm) ALUMINUM
FEEDING KIT (K1703-1)

This kit helps push feeding aluminum through standard
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 recommended for
best push feeding performance.

ALTERNATIVE MAGNUM GMAW
GUN AND CABLE ASSEMBLIES

The following Magnum 250L gun and cable assemblies
are separately available for use with the POWER
MIG® 215. Each is rated 200 amps 60% duty cycle
and is equipped with the integrated connector, twist­lock trigger connector, fixed nozzle and insulator, and
includes a liner, diffuser, and contact tips for the wire
sizes specified:

English Wire Metric Wire

Length Part No. Size Size

10' (3.0 m) K533-1
12' (3.6 m) K533-2 .035 – .045" 0.9 – 1.2 mm
15' (4.5 m) K533-3

10' *3.0 m) K533-4
12' (3.6 m) K533-5 .025 – .030" 0.6 – 0.8 mm
15' (4.5 m) K533-6

TABLE C.2

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.

Kit includes drive rolls and wire guide plate for the wire
drive, liner and two contact tips for the gun, along with
installation instructions.

READI-REEL ADAPTER (K363P)

The K363P Readi-Reel Adapter mounts to the 2" spin­dle. It is needed to mount the 22-30 lb. Readi-Reels.

DUAL 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.

SMALL SPOOL SPINDLE ADAPTER
(K468)

The K468 spindle adapter allows the use of 8" diame­ter small spools.

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® 215.

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 assembly
with a single connecting plug and trigger 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® 215
before installing the Spool Gun and Kit.

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POWER MIG® 215

ACCESSORIES

C-3C-3

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 posi­tioned 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 feeder
gun.

• Disables spool gun operation and spool gun gas

solenoid valve.

• Closing feeder gun trigger starts feeder gun

welding and makes both electrodes electrically
“HOT”.

5. To return to normal POWER MIG® 215 welding,
release the spool gun trigger set spool gun selector
switch to normal and reset feeder gun voltage pro­cedure setting if necessary.

2. Setting spool gun selector switch to the Spool Gun
Position and pulling SPOOL GUN Trigger.

• Disables built-in feeder gun operation and

machine gas solenoid valve.

• Enables spool gun operation and spool gun gas

solenoid valve.

• Closing spool gun trigger starts spool gun weld-

ing and makes both electrodes electrically
“HOT”.

3. Operation with POWER MIG® 215:

• Turn the POWER MIG®-215 input power ON.

• Adjusting the voltage tap control will increase or
decrease your welding voltage.

• Adjusting the wire speed control on the spool
gun will increase or decrease the spool gun wire
feed speed. NOTE: Adjusting the wire feed
speed control on the POWER MIG® Panel has
no affect on the spool gun’s wire feed speed.

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4. Refer to the procedure decal on the POWER MIG®
for initial aluminum settings. Make a test weld to
determine the final settings.

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POWER MIG® 215

NOTES

C-4C-4

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POWER MIG® 215

TABLE OF CONTENTS

- MAINTENANCE SECTION -

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

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Drive Rolls and Guide Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Contact Tip and Gas Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Gun Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Liner Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Gun Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

Accessories and replacement parts for Magnum

250L Gun & Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5

Section DSection D

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POWER MIG® 215

MAINTENANCE

D-2D-2

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• 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 pas­sages 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.

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.

• 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 con­tact 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.

DRIVE ROLLS AND GUIDE PLATES

After every coil of wire, inspect the wire drive mecha­nism. Clean it as necessary by blowing with low pres­sure 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. If 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 electrode
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.)

GUN 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 contact tip from
the gun. Using an air hose and only partial pressure,
gently blow out the cable liner from the gas diffuser
end.

CAUTION

Excessive pressure at the beginning of the clean­ing procedure 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 problems
are experienced, try liner replacement, and refer to
trouble shooting section on rough wire feeding.

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POWER MIG® 215

MAINTENANCE

SET SCREW

SET SCREW

BRASS CABLE CONNECTOR

GAS DIFFUSER

NOZZLE INSULATOR (IF USED)

GAS NOZZLE

1-1/4"

(31.8mm)

LINER

TRIM

LENGTH

LINER REMOVAL AND REPLACE­MENT

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

Replacement Size Stencilled Gas Diffuser Gas Diffuser

Diameter of Liner Part on End of Part No. Part No.

Electrodes Used Number Liner Bushing (and Stencil) (and Stencil)

.025-.030" Steel KP1934-2 .030 (0.8 mm) KP2026-3 KP2026-2

(0.6-0.8 mm)

.035-.045" Steel KP1934-1 .045 (1.2 mm) KP2026-3 KP2026-2

(0.9-1.2 mm)

3/64" Aluminum KP1955-1 3/64" (1.2 mm) KP2026-3 KP2026-2

(1.2 mm)

LINER REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR
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.

D-3D-3

Fixed Adjustable

Nozzle Nozzle

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 diffuser
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

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 connec­tor 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 stencilled
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 diffuser 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.

CAUTION

This screw should only be gently tightened.
Overtightening will split or collapse the liner and
cause poor wire feeding.

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POWER MIG® 215

MAINTENANCE

D-4D-4

GUN HANDLE DISASSEMBLY

The internal parts of the gun handle may be
inspected or serviced if necessary.

The gun handle consists of two halves that are
held together with a collar on each end. To open
up the handle, turn the collars approximately 60
degrees counterclockwise (the same direction
as removing a right hand thread) until the collar
reaches a stop. Then pull the collar off the gun
handle. If the collars are difficult to turn, position
the gun handle against a corner, place a screw­driver against the tab on the collar and give the
screwdriver a sharp blow to turn the collar past
an internal locking rib.

Counterclockwise



TABLE D.2

ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS

FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES

English Metric

Description Part No. Size Size

CABLE LINER

For 15' (4.5 m) or KP1934-2 .025 – .030" 0.6 – 0.8 mm

shorter Cable KP1934-1 .035 – .045" 0.9 – 1.2 mm

KP1955-1 3/64" 1.2 mm

(Alum. wire) (Alum. wire)

CONTACT TIPS
Standard Duty KP2020-6B1 .025" 0.6 mm

KP2020-7B1 .030" 0.8 mm
KP2020-1B1* .035" 0.9 mm
KP2020-2B1 .045" 1.2 mm

Heavy Duty KP2021-1B1 .035" 0.9 mm

KP2020-2B1 .045" 1.2 mm

Tapered KP2022-5B1 .025" 0.6 mm

KP2022-6B1 .030" 0.8 mm
KP2022-1B1 .035" 0.9 mm
KP2022-2B1 .045" 1.2 mm

Tab (For Aluminum) KP2010-5B1 3/64" 1.2 mm

(Alum. Wire) (Alum. Wire)

GAS NOZZLES
Fixed (Flush) KP1931-1 3/8" 9.5 mm

KP1931-2 * 1/2" 12.7 mm
KP1931-3 5/8" 15.9 mm

Fi (Recessed) KP1930-1 3/8" 9.5 mm

KP1930-2 1/2" 12.7 mm

KP1930-3 5/8" 15.9 mm
Requires: Gas
Diffuser As'bly KP2026-3 * .025 – .045" 0.6 – 1.2 mm

Adjustable Slip-On KP1935-2 1/2" 12.7 mm

KP1935-1 5/8" 15.9 mm
Requires:
Nozzle Insulator KP2025-1
As’bly

Requires:
Gas Diffuser KP2026-2 .025 – .030" 0.6 – 0.8 mm
As’bly KP2026-1 .035 – .045" 0.9 – 1.2 mm

Gasless Nozzle KP1947-1 ∆
(For Innershield)

GUN TUBE ASSEMBLIES

Standard (60°) KP2015-1 *
45° KP2041-1

* Included with POWER MIG® 215
∆ Requires KP2026-1 Gas Diffuser Assembly.

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POWER MIG® 215

MAINTENANCE

6

2

3

4

5

1

FIGURE D.2 – MAJOR COMPONENT LOCATIONS

1. Case Front Assembly

2. Rear Panel Assembly

3. Center Assembly

4. Wire Drive Assembly

5. Base & Power Component Assembly

6. Covers Assembly

D-5D-5

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POWER MIG® 215

NOTES

D-6D-6

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POWER MIG® 215