Lincoln Electric IMT10097 User Manual [en, de, es, fr]
IMT10097
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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.
POWER MIG®216
For use with machine Code Numbers
For use with machine Code Numbers
11817
May, 2011
OPERATORʼS MANUAL
MANUAL DE OPERACIÓN
OPERATOR’S MANUAL
Copyright © 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
MANUEL DE LʼOPÉRATEUR
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding 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.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
vapors
OPERATORʼS MANUAL
to
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs 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.
NOTES
OPERATORʼS MANUAL
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
TABLE OF CONTENT
Page
________________________________________________________________________
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions.................................................................................................A-2
Uncrating the POWER MIG® 216 .........................................................................A-2
Location .................................................................................................................A-2
Input Power, Grounding and Connection Diagram ........................................A-2, A-3
Output Polarity Connections..................................................................................A-3
Gun and Cable Installation ....................................................................................A-4
Shielding Gas ........................................................................................................A-4
Coil Claw™ Installation..........................................................................................A-5
________________________________________________________________________
vi vi
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
Product Description ...............................................................................................B-2
Recommended Processes and Equipment ...........................................................B-2
Welding Capability.................................................................................................B-2
Limitations..............................................................................................................B-2
Description of Controls ..........................................................................................B-2
Wire Drive Roll.......................................................................................................B-3
Wire Size Conversion parts ...................................................................................B-3
Procedure for Changing Drive Roll........................................................................B-3
Wire Reel Loading .................................................................................................B-3
Mounting of 10 to 44 lbs. Spools ...........................................................................B-3
To Start the Welder................................................................................................B-4
Feeding Electrode..................................................................................................B-4
Idle Roll Pressure Setting ......................................................................................B-4
Wire Drive Configuration................................................................................B-4, B-5
Making a Weld.......................................................................................................B-5
Avoiding Wire Feeding Problems ..........................................................................B-6
Fan Control............................................................................................................B-6
Input Line Voltage Protection.................................................................................B-6
Wire Feed overload Protection ..............................................................................B-6
Welding Thermal Overload Protection...................................................................B-6
Welding Procedure Information .............................................................................B-6
Learning To Weld ..................................................................................................B-6
________________________________________________________________________
OPERATORʼS MANUAL
Accessories.....................................................................................................Section C
Drive Roll Kits........................................................................................................C-1
Dual Cylinder Mounting Kit ...................................................................................C-1
Small Spool Spindle Adapter.................................................................................C-1
Alternative Magnum GMAW Gun and Cable Assemblies .....................................C-1
Magnum Gun Connection Kit ...............................................................................C-1
Optional Spool Guns and Adapters.......................................................................C-1
Making a Weld with the Spool Gun Adapter Kit and Spool Gun Installed .............C-2
________________________________________________________________________
vii vii
TABLE OF CONTENTS
Page
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Maintenance ............................................................................................D-1
Drive Rolls and guide Tubes .................................................................................D-1
Contact Tip and Gas Nozzle Installation ...............................................................D-1
Gun Tubes and Nozzles........................................................................................D-1
Gun Cable Cleaning ..............................................................................................D-1
Liner Removal and Replacement ..........................................................................D-2
Gun Handle Disassembly......................................................................................D-3
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ............................................................................E-2 thru E-4
Application Chart, Wiring Diagram and Dimension Print............................Section F
Parts Manual....................................................................................................Appendix
POWER MIG® 216 ..................................................................................................P-611
Magnum Pro 250L Gun ..............................................................................P-202-H.2
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – POWER MIG® 216
INPUT – SINGLE PHASE ONLY
Standard Voltage/Phase/Frequency
208/230/1/60 Hz 33/29 Amps 40/36 Amps
220/1/50 Hz 30 Amps 37 Amps
Duty Cycle Amps Volts at Rated Amperes
30% 216 Amps 22 Volts
40% 190 Amps 23 Volts
60% 170 Amps 24
Welding Current Range Maximum Open Circuit Voltage Welding Voltage Range
30 – 250Amps 36 Volts 13-24 Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES
Input Voltage/ Fuse or Breaker Rating On
Frequency (Hz) Size (Super Lag) Nameplate
Input Current @ 170 Amp Rated Output Input Current @ 216 Amp Rated Output
RATED OUTPUT
OUTPUT
Input Ampere Power Cord
(30% Duty Cycle)
A-1
* Volts
OPERATORʼS MANUAL
208/60 50 40A 50 Amp, 250V
230/60 50 36A Three Prong Plug
220/50 50 37A (NEMA) Type 6-50P)
WIRE SPEED RANGE
Wire Speed 50 – 700 IPM (1.27 – 17.8 m/minute)
PHYSICAL DIMENSIONS
Height Width Depth Weight
With Coil Claw™ Without Coil Claw™
32.56 in. 20.12 in. 19.15 in. 39.92 in. 215.5 Ibs. 206.5 lbs.
827 mm 512 mm 487 mm 1014 mm 97.8 kg. 93.7 kg.
With Gun and Cable Without Gun and Cable
and Work Cable and Work Cable
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)
* 23 Volts at 50 Hz.
POWER MIG® 216
A-2
INSTALLATION
A-2
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® 216 Operatorʼs Manual
should install and operate this
equipment.
• Machine must be grounded per
any national, local or other applicable electrical codes.
• The POWER MIG® 216 power
switch is to be in the OFF position when installing work cable
and gun and when connecting
other equipment.
UNCRATING THE POWER MIG® 216
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 brickwork in the back
and the louvers out the front. A location that minimizes
the amount of smoke and dirt drawn into the rear
brickwork reduces the chance of dirt accumulation
that can block air passages and cause overheating.
INPUT POWER, GROUNDING AND
CONNECTION DIAGRAM
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 rating plate. 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 rating plate (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.
WARNING
Make certain that the input power is electrically
disconnected before removing the screw on the
reconnect panel access cover.
------------------------------------------------------------------------
POWER MIG® 216
INSTALLATION
FIGURE A.1 — Dual Voltage Machine Input Connections
WARNING ADVERTISSEMENT ADVERTENCIA
Disconnect input power before inspecting
or servicing machine.
Do not operate with covers removed.
Do not touch electrically live parts.
Use CU wire only .
Install and Ground machine per National Electrical Code and local codes. Use Grounding Stud or Lug inside.
Only qualified persons should install, use, or service this equipment.
Consult instruction manual before installing or operating.
Débrancher l’alimentation d’entrée avant de réaliser l’inspection ou l’entretien de la machine.
Ne pas faire fonctionner sans les couvercles.
Ne pas toucher les pièces sous alimentation électrique.
Utiliser uniquement du fil CU.
Installer et mettre la machine à la terre conformément au Code Électrique National et aux réglementations locales.
Utiliser une Borne ou un Ergot de Terre à l’intérieur.
Seules des personnes qualifiées peuvent installer
Consulter le Manuel d’Instructions avant d’installer ou de faire fonctionner la machine.
Desconecte elcable de alimentación antes de iniciar caulquier inspeccion ó servicio.
No opere la máquina con las cubiertas removidas.
No toque las partes elécticas vivas.
Use solo cable con alambre de cobre.
Instale y aterrice la máquina de acuerdo a las normas eléctricas locales y nacionales. Use el Tornillo de
Tierra de la máquina.
Únicamente personal calificado debe instalar
Antes de instaler u poerar éste equipo consulte el Manual de Intruccion.
INPUT SUPPLY CONNECTION DIAGRAM
DIAGRAMME DE CONNEXION DE L’ALIMENTATION D’ENTRÉE
DIAGRAMA DE CONEXION DE LA FUENTE DE ENTRADA
Connect leads for
desired voltage range
Connecter les câbles
pour obtenir la tension
désirée.
Conecte cable selector
para el voltage de
alimentacion deseado.
, utilizar ó dar servicio a éste equipo.
ELECTRIC SHOCK can kill
LES CHOCS ÉLECTRIQUES peuvent être mortels
DESCARGAS ELECTRICAS pueden matar
, utiliser ou réaliser l’entretien de cet appareil.
SINGLE PHASE
MONOPHASE
MONOFASICO
A-3 A-3
OPERATORʼS MANUAL
RECONNECT
RECONEXION
REBRANCHER
ALIMENTACION
INPUT
ENTRÉE
3. The 208/230 volts 50/60 Hz model POWER MIG is
shipped with a 10ft.(3.0m) input cable and plug
connected to the welder.
4. 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.
OUTPUT POLARITY CONNECTIONS
The welder, as shipped from the factory, is connected
for electrode positive (+) polarity. This is the normal
polarity for GMAW.
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.
POWER MIG® 216
A-4
INSTALLATION
GUN AND CABLE INSTALLATION
The Magnum Pro 250L gun and cable provided with the
POWER MIG® 216 is factory installed with a liner for .035.045" (0.9-1.1 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 the Hand Screw on the drive unit front end
(inside wire feed compartment) until tip of screw no
longer protrudes into Gun Adapter opening as seen
from front of machine. (See Figure A.2)
3. Insert the male end of gun cable into the Gun Adapter
through the opening in front panel. Make sure connector
is fully inserted and tighten Hand Screw.
4. Connect the Gun Trigger Connector from the gun and
cable to the mating Receptacle outside the compartment
located left of the opening on the Front Panel. Make sure
that the keyways are aligned, insert and tighten retaining
ring.
SHIELDING GAS
[For Gas Metal Arc Welding(GMAW) 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® 216.
When using 100% CO2an additional adapter will be
required to connect the regulator to the gas bottle.
A-4
INSTALL SHIELDING GAS SUPPLY AS FOLLOWS:
1. Set gas cylinder on rear platform of POWER MIG® 216.
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 100% CO
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 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®
216 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.
cylinder, an additional
2
2
WARNING
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.
------------------------------------------------------------------------
POWER MIG® 216
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.
FIGURE A.2
Hand Screw
Gun Adapter
Male End
Gun and Cable
Receptacle
Gun Trigger
Connector
A-5
INSTALLATION
COIL CLAW™ INSTALLATION
The Coil Claw™ and mounting screws are provided
as an optional accessory for the POWER MIG® 216.
This user-install accessory provides cable management for the machine.
WARNING
Turn the welder power switch OFF
before installing Coil Claw™.
------------------------------------------------------------------------
1. Unwrap Coil Claw™ from its protective paper and
remove the bag of mounting screws from the back
of the Coil Claw™.
2. Mount
ing screws to the left side of the machine, when
viewed from the front. Make sure the Coil Claw™ is
firmly mounted. (See Figure A.3)
the Coil Claw™ using the provided mount-
A-5
OPERATORʼS MANUAL
MOUNTING
SCREWS
FIGURE A.3
COIL CLAW™
POWER MIG® 216
B-1
OPERATION
Read entire Operation section before
operating the POWER MIG® 216.
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-1
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.
------------------------------------------------------------
POWER MIG® 216
B-2 B-2
3
2
1
4
5
OPERATION
PRODUCT DESCRIPTION
The POWER MIG® 216 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 and 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. An enhanced feature to the
POWER MIG® 216, is that it is Magnum 100SG Spool
Gun ready.
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 Pro 250L GMAW gun
and cable with fixed (flush) nozzle, a 10 ft. (3.0 m)
power cable with plug, and a 10 ft. (3.0 m) work cable
with clamp.
Optional Magnum Spool Gun, Adapter kits and Dual
Cylinder Mounting kit for push feeding with standard
built in feeder are also available.
RECOMMENDED PROCESSES AND
EQUIPMENT
LIMITATIONS
The output voltage/current of the POWER MIG® 216
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 - Press the switch to "ON"
position to energize the POWER MIG® 216.
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 Application
Chart / Procedure Decal on the inside of the wire
compartment door or Section F of this Instruction
Manual.
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.
4. 4-Pin Connector - For Push Gun and Spool Gun
Operations.
FIGURE B.1
OPERATORʼS MANUAL
The POWER MIG® 216 is recommended for GMAW
processes using 10 to 44 lb (4.5 to 20 kg) 2" (51 mm)
I.D. spools of .025" through .045" (0.6 – 1.1 mm) solid
wire, .035" (0.9 mm) stainless, 3/64" (1.2 mm) aluminum, .035” (0.9 mm), .045" (1.1 mm) Outershield
and .045”(1.1mm) Ultracore® as well as .035" (0.9
mm) and .045" (1.1 mm) Innershield®self-shielding
electrodes.
The POWER MIG® 216 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.
®
5. Magnum Push Gun and Spool Gun toggle
switch - Toggle the switch (Item 5 see Figure B.2)
to select between push gun and spool gun. When
either operation is selected, insert the cable to 4-pin
Connector. (Item 4, See Figure B.1)
FIGURE B.2
WELDING CAPABILITY
The POWER MIG® 216 is rated at 216 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.
POWER MIG® 216
OPERATION
B-3 B-3
WIRE DRIVE ROLL
The drive rolls installed with the POWER MIG® 216
have two grooves, one for .035”(0.9mm) wire and the
other for .045”(1.1mm) wire. Drive roll size is indicated
by the stenciling on the exposed side of the drive roll.
WIRE SIZE CONVERSION PARTS
The POWER MIG® 216 is rated to feed .025” through
.045" (0.6-1.1mm) solid or cored electrode sizes.
The drive roll kits and Magnum Pro 250L gun and
cable parts are available to feed different sizes and
types of electrodes. See Accessories and
Maintenance sections of this Instruction Manual.
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.
FIGURE B.3
WIRE REEL LOADING - SPOOLS
OR COILS
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 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: The arrow marked 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 “pops up” and that the collar retainers
fully engage the retaining ring groove on the spindle.
UNLOCKED POSITION
(See Figure B.3)
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.
LOCKED POSITION
POWER MIG® 216
B-4
OPERATION
B-4
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.
The pressure arm controls the amount of force the drive
rolls exert on the wire. Proper adjustment of pressure
arm gives the best welding performance. For best
results, set pressure arm to the suggested value.
FEEDING WIRE ELECTRODE
Set the pressure arm as follows (See Figure B.4):
WARNING
When triggering, the electrode and
drive mechanism are electrically
“hot” relative to work and ground and
remain “hot” for 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 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.
WIRE DRIVE CONFIGURATION
See Figure B.5
Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6
FIGURE B.4
CORED WIRES
OU TE R S HI E L D
METAL SHIELD
INNERSHIELD
1
3
5
SOLID WIRES
2
4
6
ALUMINUM
STEEL
STAINLESS
OPERATORʼS MANUAL
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® 216
Changing the Gun Adapter
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 adapters do not require the use of
the hand screw.
1. Turn power OFF at the welding power source.
2. Remove the welding wire from the wire drive.
3. Remove the hand screw from the wire drive.
4. Remove the welding gun from the wire drive.
B-5 B-5
5. Loosen the socket head cap screw that holds the
connector bar against the gun adapter.
Important: Do not attempt to completely
remove the socket head cap screw.
OPERATION
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®].
6. Remove the outer wire guide, and push the gun
adapter out of the wire drive. Because of the precision fit, light tapping may be required to remove
the gun adapter.
4. When welding with gas, turn on the gas supply and
set the required flow rate (typically 30-40 CFH; 1419 liters/min).
7. Disconnect the shielding gas hose from the gun
adapter, if required.
8. Connect the shielding gas hose to the new gun
adapter, if required.
9. Rotate the gun adapter until the hand screw hole
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”.
aligns with the hand screw hole in the feed plate.
Slide the gun adapter into the wire drive and verify
the hand screw holes are aligned.
10. Tighten the socket head cap screw.
11. Insert the welding gun into the gun adapter and
tighten the hand screw.
• When using an open arc process, it
is necessary to use correct eye,
head, and body protection.
WARNING
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 and thickness, and gas (for MIG and Outershield
used. Use the Application Chart on the door inside
the wire compartment as a quick reference for
some common welding procedures.
NOTE: Application Chart can also be found in
Section F of this Instruction Manual.
GUN ADAPTER
®
) being
Figure B.5
-----------------------------------------------------------------------
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 that the contact tip
to work distance is about 3/8" (10 mm) [3/4" (20
mm) for Outershield®].
8. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN TIGHTEN
POWER MIG® 216
OUTER WIRE GUIDE
HAND SCREW
OPERATION
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® 216.
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.
B-6 B-6
WIRE FEED OVERLOAD
PROTECTION
The POWER MIG® 216 has solid state overload protection of the wire drive motor. If the motor becomes
overloaded, the protection circuitry turns off the wire
drive motor 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® 216 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.
WELDING PROCEDURE
INFORMATION
NOTE: See inside cover of machine or Section F of this
Instruction Manual for additional, commonly used welding
procedure.
LEARNING TO WELD
OPERATORʼS MANUAL
FAN CONTROL
The fan is designed to come on when input power is
applied to the POWER MIG® 216 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.
POWER MIG® 216
Welding is a skill that can only be learned by practicing. No one can become an accomplished welder
simply by reading about it. The following link
“Learning to Weld” document will help the inexperienced operator to understand the basics about wire
welding and provide guidance to help develop this
skill.
“Learning to Weld” link:
http://content.lincolnelectric.com/pdfs/products/
navigator/im/LTW1tri.pdf
C-1 C-1
ACCESSORIES
DRIVE ROLL KITS
Refer to Table C.1 for various drive roll kits that are
available for the POWER MIG® 216.The item in Bold
is supplied standard with the POWER MIG® 216.
TABLE C.1
Wire Size Drive Roll Kit
Solid
Steel
Cored
Aluminum
.023”-.030” (0.6-0.8 mm)
.035” (0.9 mm) KP1696-035S
.045” (1.1 mm) KP1696-045S
.035”-.045” (0.9-1.1mm) KP1696-1
.040” (1.0mm) KP1696-2
.035” (0.9 mm) KP1697-035C
.045” (1.1 mm) KP1697-045C
3/64” (1.2 mm) KP1695-3/64A
KP1696-030S
DUAL CYLINDER MOUNTING KIT
(K1702-1)
Permits stable side-by-side mounting of two full size
228.6mm dia x 1.524m high(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)
ALTERNATIVE MAGNUM GMAW
GUN AND CABLE ASSEMBLIES
The following Magnum Pro 250L gun and cable
assemblies are separately available for use with the
POWER MIG® 216. Each is rated at 250 amps 40%
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
Length Part No. Size Size
10' (3.0 m)
12' (3.6 m) KP42-4045-15 .035” – .045" 0.9 – 1.1 mm
15' (4.5 m)
WARNING
• Unplug or Disconnect all input power
from the POWER MIG® 216 before
installing the Spool Gun and Kit.
------------------------------------------------------------------------
MAGNUM GUN CONNECTION KIT
(K466-6)
Using the optional K466-6 Magnum Connection kit for
the POWER MIG® 216 permits use of standard
Magnum 200, 300 or 400 gun and cable assemblies.
OPTIONAL SPOOL GUNS AND
ADAPTERS
The K468 spindle adapter allows the use of 8" diameter small spools.
SPINDLE ADAPTER FOR 14 LBS.
COILS (K435)
The K435 spindle adapter allows 14lbs. (6kg.)
Innershield Coils to be mounted on 2” (51mm) O.D.
spindle.
POWER MIG® 216
The
POWER MIG® 216
following optional spool guns:
SPOOL GUN
Magnum 100SG
(K2532-1)
Magnum SG
(K487-25)
Magnum 250LX
(K2490-1)
Spool gun Adapter (K2703-1)
This kit is designed to allow the Magnum SG or Magnum
250LX spool gun to operate with the
The kit includes the gas solenoid, gas lines, wiring harness
and gun connection panel. The gun connection panel features a 6 pin ms-type connector for the Magnum SG spool
gun and a 7 pin ms-type connector for the Magnum 250LX
spool gun and a selector switch to choose which gun you
are using.
NOTE: The K2703-1 spool gun adapter disables the
Magnum 100SG capability.
130amp 30% Duty Cycle
250Amp 60% Duty Cycle
300 Amp 60% Duty Cycle
is capable of operating with the
RATING
Light Duty
Medium Duty
Heavy Duty
POWER MIG® 216
ADAPTER
Factory Ready
No Adapter Required
Spool Gun Adapter
K2703-1
.
C-2
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 positioned so electrode or tip will not contact metal
case or other metal common to work.
------------------------------------------------------------------------
1. Setting the toggle switch to “Push Gun” position
disables the spool gun operation and spool gun
gas solenoid valve. Closing the gun trigger enables
the push gun welding and both electrodes will be
electrically “HOT”.
2. Setting the toggle switch to the “Spool Gun” position disables the built-in push gun operation and
feeder gas solenoid valve. It will also enables the
spool gun operation and spool gun gas solenoid
valve. Closing the spool gun trigger enables spool
gun welding and both electrodes will be electrically
“HOT”.
C-2
OPERATORʼS MANUAL
3. Operation with POWER MIG® 216:
• Turn the POWER MIG® 216 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
Machineʼs Front Panel has no affect on the spool
gunʼs wire feed speed.
4. Refer to the welding procedure on the machine or
Section F of this Instruction Manual for initial aluminum settings. Make a test weld to determine the
final settings.
5. Set the spool gun selector switch to “Push Gun”
position to return to push gun operation.
POWER MIG® 216
D-1
SAFETY PRECAUTIONS
WARNING
MAINTENANCE
• Be sure the nozzle insulator is fully screwed
onto the gun tube and does not block the gas
holes in the diffuser.
D-1
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.
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.
• 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.
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
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.)
3. If using optional adjustable slip-on nozzles, see
Table D.2 in this section.
POWER MIG® 216
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.
D-2
MAINTENANCE
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
Fixed
Diameter of Liner Part on End of Part No.
Replacement Size Stencilled Gas Diffuser
Electrodes Used Number Liner Bushing (and Stencil)
.025”-.030" Steel KP42-25-15 .030” (0.8 mm)
(0.6-0.8 mm)
.035”-.045" Steel KP42-4045-15 .045” (1.1 mm) KP2746-1
(0.9-1.1 mm)
3/64" Aluminum KP42-4045-15 3/64" (1.2 mm)
(1.2 mm)
LINER REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR MAGNUM PRO 250L
Nozzle
D-2
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
SET SCREW
BRASS CABLE CONNECTOR
SET SCREW
GAS DIFFUSER
NOZZLE INSULATOR (IF USED)
GAS NOZZLE
1-1/4"
(31.8mm)
LINER
TRIM
LENGTH
OPERATORʼS MANUAL
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 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 being 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.
CAUTION
This screw should only be gently tightened.
Overtightening will split or collapse the liner and
cause poor wire feeding.
------------------------------------------------------------------------
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.
POWER MIG® 216
D-3
MAINTENANCE
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
„
D-3
TABLE D.2
ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS
FOR MAGNUM PRO 250L GUN AND CABLE ASSEMBLIES
Description Part No. Size Size
CABLE LINER
For 15' (4.5 m) or KP42-25-15 .025" – .030" 0.6 – 0.8 mm
shorter Cable KP42-4045-15 .035" – .045" 0.9 – 1.1 mm
KP42-4045-15 3/64" 1.2 mm
CONTACT TIPS
Standard Duty KP2744-025 .025" 0.6 mm
KP2744-030 .030" 0.8 mm
KP2744-035 .035" 0.9 mm
KP2744-045 .045" 1.1 mm
Tapered KP2744-030T .030" 0.8 mm
KP2744-035T .035" 0.9 mm
KP2744-045T .045" 1.1 mm
Tab (For Aluminum) KP2744-364A 3/64" 1.2 mm
GAS NOZZLES
Fixed (Flush) KP2742-1-38F 3/8" 9.5 mm
KP2742-1-50F* 1/2" 12.7 mm
KP2742-1-62F 5/8" 15.9 mm
Fixed (Recessed) KP2742-1-38R 3/8" 9.5 mm
KP2742-1-50R
KP2742-1-62R 5/8" 15.9 mm
Requires: Gas
Diffuser As'bly KP2746 * .025" – .045" 0.6 – 1.1 mm
English Metric
(Alum. wire) (Alum. wire)
(Alum. Wire) (Alum. Wire)
1/2" 12.7 mm
Insulator KP2773-2 *
GUN TUBE ASSEMBLIES
Standard (60°) KP3078-60 *
45° KP3078-45 *
* Included with POWER MIG® 216
** Tapered tips are required with 3/8” I.D. and 1/2” I.D. Nozzles.
See www.lincolnelectric.com for complete offering of Magnum Pro consumables.
POWER MIG® 216
TROUBLESHOOTING
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.
__________________________________________________________________________
E-1 E-1
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external 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.
OPERATORʼS MANUAL
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® 216
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-2 E-2
PROBLEMS
(SYMPTOMS)
Major Physical or Electrical
Damage is Evident
There is no wire feed or open circuit voltage when the gun trigger is
pulled. Input power is applied to
POWER MIG® 216.
Output voltage and wire feed is present when gun trigger is not pulled
(not activated).
POSSIBLE
CAUSE
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 correct and matches nameplate rating and reconnect panel configuration.
4. If spool gun option kit is in-
stalled, check to see that it is set
to “Push Gun” if pulling the gun
trigger associated with built in
feeder, 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® 216.
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.
Machine output is low. Welds are
“cold”, weld bead is rounded or
bumped up demonstrating poor
wetting into plate.
1. Check input voltage. Make sure
input voltage matches nameplate 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 correct for process being used.
4. Check welding cables and gun
assembly for loose or faulty connections.
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® 216
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-3 E-3
PROBLEMS
(SYMPTOMS)
Poor arc striking with electrode
sticking or blasting off.
Rough wire feeding or wire will not
feed but drive rolls are turning.
POSSIBLE
CAUSE
OUTPUT PROBLEMS
1. Make sure settings for wire feed
speed and voltage are correct
for process being used.
2. The gas shielding may be
improper for process being used.
3. Check input line voltage to be
within machineʼs recommended
rating range.
4. Check that the machine recon-
nect panel is configured properly
for the applied voltage.
FEEDING PROBLEMS
1.
The gun cable may be kinked or twisted.
2.
The wire may be jammed in the gun
cable, or gun cable may be dirty.
3. Check drive roll tension and
position of grooves.
4.
Check for worn or loose drive rolls.
5.
The electrode may be rusty or dirty.
6. Check for damaged or incorrect
contact tip.
7. Check wire spindle for ease of
rotation and adjust break tension knob if necessary.
8. Check that the gun is pushed all
the way into gun mount and
properly seated.
RECOMMENDED
COURSE OF ACTION
OPERATORʼS MANUAL
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® 216
E-4 E-4
Observe all Safety Guidelines detailed throughout this manual
TROUBLESHOOTING
PROBLEMS
(SYMPTOMS)
The wire feed stops while welding.
When trigger is released and
pulled again the wire feed starts.
No control of wire feed speed.
Other machine functions are normal.
Gas does not flow when gun trigger
is pulled.
POSSIBLE
CAUSE
FEEDING PROBLEMS
1. Check the wire feed drive rolls
and motor for smooth operation.
2. Check for restrictions in the wire
feed path. Check the gun and
cable for restrictions.
3. Make sure gun liner and tip are
correct for wire size being used.
4.
Make sure drive rolls and guide plates
are clean and are the correct size.
5. Check spindle for ease of rotation.
1. The wire feed speed control may
be dirty. Rotate several times
and check if problem is resolved.
GAS FLOW PROBLEMS
1. Make sure gas supply is connected properly and turned
“ON”.
2. If the gas solenoid does actuate
(click) when the gun trigger is
pulled, there may be a restriction
in the gas supply line.
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.
3. The gun cable assembly may be
faulty. Check or replace.
4. If gas solenoid does not operate
when gun trigger is pulled, the
problem is within the POWER
MIG® 216.
5. 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® 216
½”
APPLICATION CHART
F-1 F-1
G / 500
G / 425
E / 325 F / 375
E / 400
E / 570
E / 400
E / 575
G / 500
G / 500
G / 350 G / 350 G / 400
F / 375
F / 320
E / 280
E / 170
E / 160
G / 500
G / 300
G / 270
G / 475
F / 350
E / 320
E / 200E / 160
E / 330
D / 280
3/ 16” 1/ 4” 5/ 16” 3/ 8”
E / 180
OPERATORʼS MANUAL
E / 250 F / 300
B / 500 C / 500 D / 400 D / 410 E / 425
B / 425
D / 375
C / 375
B / 450
B / 350
B / 325
F / 230
D / 250 E / 300 F / 350
D / 200
E / 300
E / 300
D / 225 D / 350 E / 375 E / 400 F / 500
C / 180
E / 265 E / 280
C / 130 D / 150
D / 130
C / 90 C / 100
B / 80
B / 75
C / 70 C / 90 D / 110 D / 130
B / 70
D / 280
D / 300
C / 230
C / 225
C / 180
C / 175
B / 130
M at erial Thickness/ Espesor de el
material/ Lépaisseur de matériel
B / 11O
B / 90 B / 120 C / 160 C / 200 D / 240
B / 150
C / 110 D / 120 D / 140
C / 8 0
E / 400
D / 285
C / 200
C / 175
E / 350
D / 250
D / 200
C / 175
C / 140
E / 240
D / 200
D / 160
C / 120
C / 9 0
E / 150
D / 125
D / 110
D / 90
C / 7 5
E / 570
D / 485
C / 475
B / 300
A / 300
E / 390 F / 410
B / 500 C / 500 D / 450 E / 500 E / 550
B / 475
D / 375
C / 375
B / 450
B / 350
B / 325
E / 575
D / 485
C / 475
B / 325
A / 300
B / 500 C / 500 D / 400 D / 410 E / 425
B / 475
E / 250 F / 300
B / 325 B / 350 B / 450 C / 375 D / 375 E / 400
E / 575 E / 575
D / 485
A / 300 B / 300 C / 475
E / 390 F / 410
22 ga 20 ga 18 ga 16 ga 14 ga 12 ga 10 ga
R
16
2
POWER M IG
/ / / / / / / / / / /
A / 1OO
B / 125
/
.030 in .036 in .048 in .060 in .075 in .105 in .135 in .187 in .250 in .312 in .375 in .500 in
Wire Di ameter
(0.8mm) (0.9mm) (1.2mm) (1.6mm) (2.0mm) (2.5mm) (3.5mm) (4.8mm) (6.4mm) (7.9mm) (9.5mm) (12.7mm)
Dia. du f il
Dia. de alam bre
- 3/8 in.
(mm)
In.
30-40 CFH
B / 125
(0.6)
0.025
A / 75
(0.8)0.030
75%/ 25%
0.035 (0.9)
2
Ar/ CO
C / 150
C / 125
(0.8)0.030
(0.6)0.0
(0.9)0.0
25
35
0.045 (1.1)
2
100% CO
R
MIG
(DC+)
Super Arc
(1.1)0.0
45
0.035 (0.9)
2
Ar/ CO
75%/ 25%
Gas-Shielded
(1.1)0.045
Outer shield 7 1 M
(0.9)0.035
R
UltraCore 71A75
(0.9)
90%/ 7.5%/ 2.5%
BlueMax 308 LS
0.035
He/ Ar/ CO
(DC+)
(1.1)
(0.9)0.0
35
2
R
Innershield
0.045
& 212
NR-211-MP
(DC-)
(0.8)0.030
(0.9)0.035
100% Ar
R
Aluminum
SuperGlaze 4043
M AGN UM SG GUN (DC+)
(1.2)
3/64
R
Aluminum
(0.9)0.035
(1.2)
3/64
100% Ar
SuperGlaze 5356
M AGN UM SG GUN (DC+)
(0.8)0.030
R
Aluminum
(0.9)0.035
100% Ar
SuperGlaze 4043
MAGNUM 100 SG (DC+)
(0.9)0.0
R
Aluminum
SuperGlaze 5356
35
100% Ar
(0.8)0.030
(0.9)0.035
100% Ar
R
Aluminum
SuperGlaze 4043
MAGNUM 100 SG (DC+)
MAGNUM 250 LX (DC+)
(1.2)
3/64
(0.9)0.035(1.2)
3/64
100% Ar
R
Aluminum
SuperGlaze 5356
MAGNUM 250 LX (DC+)
(0.8)0.030
2
Tr i -M ix
100% CO
R
St ainless
DUAL (DC+)
POWER MIG® 216
WIRING DIAGRAMS
ENHANCED DIAGRAM
F-2 F-2
POWER MIG® 216
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on
one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
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