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POWER MIG
RETURN TO MAIN MENU
™
IM693
June, 2002
200
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.
For use with machine Code Numbers
For use with machine Code Numbers
10564
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2001 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Page 2
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.
POWER MIG 200
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.
Mar ‘95
Page 3
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.
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 below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
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.
5.b.
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.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
vapors
Mar ‘95
to
POWER MIG 200
Page 4
iii
SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
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.
Remember that welding sparks and hot
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.
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.
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.
Mar ‘95
POWER MIG 200
Page 5
iv
SAFETY
iv
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.
zones où l’on pique le laitier.
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.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du 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
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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.
Mar. ‘93
POWER MIG 200
Page 6
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
vv
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
Page 7
vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions.................................................................................................A-2
Uncrating the POWER MIG 200............................................................................A-2
Location .................................................................................................................A-2
Input Power, Grounding and connection Diagrams .................................A-2 thru A-3
Output Polarity Connections..................................................................................A-3
Gun and Cable Installation ....................................................................................A-4
Shielding Gas ........................................................................................................A-4
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-2
Wire Size Conversion parts ...................................................................................B-2
Procedure for Changing Drive Roll........................................................................B-3
Wire Reel Loading .................................................................................................B-3
Mounting of 10 to 30 lbs. Spools ...........................................................................B-3
To Start the Welder................................................................................................B-3
Feeding Electrode..................................................................................................B-4
Idle Roll Pressure Setting ......................................................................................B-4
Making a Weld.......................................................................................................B-4
Avoiding Wire Feeding Problems ..........................................................................B-5
Fan Control............................................................................................................B-5
Input Line Voltage Protection.................................................................................B-5
Wire Feed overload Protection ..............................................................................B-5
Welding Thermal Overload Protection...................................................................B-5
vi
Accessories.....................................................................................................Section C
Drive Roll Kits........................................................................................................C-1
Aluminum Feeding Kit (Optional K1703-1)............................................................C-1
K363P Readi-Reel Adapter ...................................................................................C-1
Dual Cylinder Mounting Kit (K1702-1)...................................................................C-1
Alternative Magnum GMAW Gun and Cable Assemblies .....................................C-1
Magnum Gun Connection Kit (Optional K466-6)...................................................C-1
Spool Gun and Adapter Kit (Optional K1809-1) ....................................................C-1
Making a Weld with the Spool Gun Adapter Kit and Spool Gun Installed .............C-2
POWER MIG 200
Page 8
vii
MASTER TABLE OF CONTENTS FOR ALL SECTIONS (cont.)
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
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
Wiring Diagram and Dimension Print............................................................Section F
Parts Manual....................................................................................................Appendix
POWER MIG 200 ..................................................................................P372 Series
Magnum 250L Gun .....................................................................................P202-H.2
vii
POWER MIG 200
Page 9
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – POWER MIG 200
INPUT – SINGLE PHASE ONLY
A-1
Standard
Voltage/Frequency
208/230/50/60 Hz 28/26 Amps 36/33
Input Current @ 150 Amp Rated Output Input Current @ 150 Amp Rated Output
RATED OUTPUT
Duty
Cycle Amps Volts at Rated Amperes
30% 200 Amps 22 Volts
40% 180 Amps 23 Volts
60% 150 Amps 24 Volts
OUTPUT
Welding
Current Range Maximum Open Circuit Voltage Welding Voltage Range
30 – 200 Amps 40 Volts 13.5-22 Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES
75°C Copper Wire 75°C Copper Wire
Input Ampere in Conduit in Conduit
Input Voltage/ Fuse or Breaker Rating On AWG (IEC) Sizes AWG (IEC) Sizes
(For lengths (For lengths
Frequency (Hz) Size (Super Lag) Nameplate up to 100 ft.) exceeding 100 ft.)
208/50/60 60 36 10 (6 mm
230/50/60 60 33 10 (6 mm2) 8 (10 mm2)
2
) 8 (10 mm2)
NOTE: Use #10 AWG Grounding Wire
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
WIRE SPEED RANGE
Wire Speed 50 – 700 IPM (1.27 – 17.8 m/minute)
POWER MIG 200
Page 10
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 200 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 200
Cut banding and lift off cardboard carton. Cut banding
holding the machine to the skid. Remove foam and
corrugated packing material. Untape accessories from
Gas Bottle Platform. Unscrew the two wood screws
(at the Gas Bottle Platform) holding the machine to
the skid. Roll the machine off the skid assembly.
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 and Figure A.2 for triple 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.
POWER MIG 200
Page 11
INSTALLATION
FIGURE A.1 — Dual Voltage Machine Input Connections
A-3A-3
50/60 HZ
3. The 208/230 volt 50/60 Hz model POWER MIG is
shipped with a 7 ft. input cable and plug connected
to the welder.
4. Using the instructions in Figure A.3, 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.3 — 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.
CONNECT TO HOT WIRES
OF A THREE-WIRE, SINGLE
PHASE SYSTEM OR TO ONE
PHASE OF A TWO OR
THREE PHASE SYSTEM.
FIGURE A.3 — 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.
CONNECT TO HOT WIRES
OF A THREE-WIRE, SINGLE
PHASE SYSTEM OR TO ONE
PHASE OF A TWO OR
THREE PHASE SYSTEM.
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.
POWER MIG 200
Page 12
A-4
INSTALLATION
GUN AND CABLE INSTALLATION
The Magnum 250L gun and cable provided with the
POWER MIG 200 is factory installed with a liner for
.035-.045" (0.9-1.2 mm) electrode and an .035" (0.9
mm) contact tip. Be sure that the contact tip, liner, and
drive rolls all match the size of the wire being used.
WARNING
Turn the welder power switch off before installing
gun and cable.
1. Lay the cable out straight.
2. Unscrew knurled screw on the drive unit front end
(inside wire feed compartment) until tip of screw no
longer protrudes into gun opening as seen from
front of machine.
A-4
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.
3. Insert the male end of gun cable into the female
casting through opening in front panel. Make sure
connector is fully inserted and tighten knurled
screw.
4. Connect the gun trigger connector from the gun
and cable to the mating receptacle inside the 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
200. When using 100% CO
be required to connect the regulator to the gas bottle.
an additional adapter will
2
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:
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
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 CO
5. Attach one end of the inlet gas hose to the outlet
fitting of the flow regulator, the other end to the
POWER MIG 200 rear fitting, and tighten the union
nuts securely with a wrench.
6. Before opening the cylinder valve, turn the 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
2
cylinder.
2
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.
1. Set gas cylinder on rear platform of POWER MIG
200. Hook chain in place to secure cylinder to rear
of welder.
POWER MIG 200
Page 13
B-1
OPERATION
Read entire Operation section before
operating the POWER MIG 200.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
• 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 contain-
ers.
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protection.
Observe all safety information throughout
this manual.
POWER MIG 200
Page 14
B-2
OPERATION
B-2
PRODUCT DESCRIPTION
The POWER MIG™ 200 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 12 ft. (3.6 m) Magnum 250L GMAW gun and
cable with fixed (flush) nozzle, a 7 ft. (2.1 m) power
cable with plug, and a 10 ft. (3.0 m) work cable with
clamp.
Optional Spool Gun and Adapter kit, Dual Cylinder
Mounting kit and Aluminum Feeding Kit for push feeding with standard built in feeder are also available.
LIMITATIONS
The output voltage/current of the POWER MIG 200 is
subject to vary if the input power to the machine
varies, due to its tapped transformer power topology.
In some cases an adjustment of WFS preset and/or
voltage tap selection may be required to accommodate a significant drift in input power.
DESCRIPTION OF CONTROLS
Power ON/OFF Switch — Place the lever in the "ON"
position to energize the POWER MIG 200.
Voltage Control — Seven voltage tap selections are
provided Labeled "A" (minimum voltage) through "G"
(maximum voltage). It should only be adjusted when
not welding. The control selection can be preset to the
setting specified on the Procedure Decal on the inside
of the wire compartment door.
Wire Speed Control — This controls the wire feed
speed from 50 – 700 inches per minute (1.2 – 17.8
m/min). Wire speed is not affected when changes are
made in the voltage control.
RECOMMENDED PROCESSES AND
EQUIPMENT
The POWER MIG 200 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 .045" (1.2 mm) Outershield
.035" (0.9 mm) and .045" (1.2 mm) Innershield®selfshielding 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, 12 ft. (3.6
m) GMAW gun and cable assembly equipped for
these wire sizes. Use of GMAW processes requires a
supply of shielding gas.
®
; as well as
WELDING CAPABILITY
The POWER MIG 200 is rated at 200 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 each
have two grooves, both for .030-.035" (0.8-0.9 mm)
solid steel electrode. Drive roll size is indicated by the
stenciling on the exposed side of the drive roll. If feeding problems occur, then the drive roll may be
reversed or changed. See "Procedure for Changing
Drive Roll" in this section.
WIRE SIZE CONVERSION PARTS
The POWER MIG 200 is rated to feed .025 through
.045" (0.6-1.2 mm) solid or cored electrode sizes.
The drive roll kits and Magnum 250L gun and cable
parts are available to feed different sizes and types of
electrodes. See Accessories section.
POWER MIG 200
Page 15
B-3
OPERATION
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 roll. (See Figure A.4)
FIGURE A.4
B-3
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.
FIGURE B.1
UNLOCKED POSITION
5. Remove the inside wire guide plate.
6. Replace the drive and idle rolls and inside wire
guide with a set marked for the new wire size.
NOTE: Be sure that the gun liner and contact tip
are also sized to match the selected wire size.
7. Manually feed the wire from the wire reel, over the
drive roll groove and through the wire guide and
then into the brass bushing of the gun and cable
assembly.
8. Replace the outside wire guide retaining plate by
tightening the two large knurled screws. Reposition
the adjustable pressure arm to its original position
to apply pressure. Adjust pressure as necessary.
WIRE REEL LOADING - READI-REELS,
LOCKED 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
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 at the 12
o'clock position.
POWER MIG 200
2. Depress the Release Bar on the Retaining Collar and remove it
from the spindle.
3. Place the spool on the spindle making certain the spindle brake
pin enters one of the holes in the back side of the spool (Note:
an arrow mark on the spindle lines up with the brake holding pin
to assist in lining up a hole). Be certain the wire comes off the
reel in a direction so as to de-reel from the top of the coil.
4. Re-install the Retaining Collar. Make sure that the Release Bar
“pops up” and that the collar retainers fully engage the retaining
ring groove on the spindle.
TO START THE WELDER
Turn the “Power Switch” switch to “ON”. This lights the red LED display lights. With the desired voltage and wire speed selected, operate the gun trigger for welder output and to energize the wire feed
motor.
Page 16
B-4
FEEDING WIRE ELECTRODE
OPERATION
MAKING A WELD
B-4
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.
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 GMAW) being used. Use the
Application Chart on the door inside the wire compartment as a quick reference for some common
welding procedures.
3. Press the trigger to feed the wire electrode through
the gun and cable and then cut the electrode within
approximately 3/8" (10 mm) of the end of the contact tip [3/4" (20 mm) Outershield
4. If welding gas is to be used, turn on the gas supply
and set the required flow rate (typically 25-35 CFH;
12-16 liters/min).
5. When using Innershield electrode, the gas nozzle
may be removed from the insulation on the end of
the gun and replaced with the gasless nozzle. This
will give improved visibility and eliminate the possibility of the gas nozzle overheating.
6. Connect work cable to metal to be welded. Work
clamp must make good electrical contact to the
work. The work must also be grounded as stated in
“Arc Welding Safety Precautions”.
®
].
4. Press gun trigger to feed the electrode wire
through the gun.
IDLE ROLL PRESSURE SETTING
The optimum idle roll pressure varies with type of
wire, wire diameter, surface conditions, lubrication,
and hardness. As a general rule, hard wires may
require greater pressure, and soft, or aluminum wire,
may require less pressure than the factory setting.
The optimum idle roll setting can be determined as
follows:
1. Press end of gun against a solid object that is electrically isolated from the welder output and press
the gun trigger for several seconds.
2. If the wire “birdnests”, jams or breaks at the drive
roll, the idle roll pressure is too great. Back the
adjustment knob out 1/2 turn, run new wire through
gun, and repeat above steps.
3. If the only result was drive roll slippage, loosen the
adjustment knob on the conductor plate and pull
the gun cable forward about 6" (15 cm). There
should be a slight waviness in the expose wire. If
there is not waviness, the pressure is too low.
Tighten the adjustment knob 1/4 turn, reinstall the
gun cable and repeat the above steps.
POWER MIG 200
WARNING
When using an open arc process, it is necessary
to use correct eye, head, and body protection.
7. Position electrode over joint. End of electrode
may be lightly touching the work.
8. Lower welding helmet, close gun trigger, and
begin welding. Hold the gun so the contact tip to
work distance is about 3/8" (10 mm) [3/4" (20
mm) for Outershield].
9. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc
goes out.
10. When no more welding is to be done, close valve
on gas cylinder (if used), momentarily operate
gun trigger to release gas pressure, and turn off
POWER MIG 200.
Page 17
B-5
OPERATION
B-5
AVOIDING WIRE FEEDING
PROBLEMS
Wire feeding problems can be avoided by observing
the following gun handling procedures:
1. Do not kink or pull cable around sharp corners.
2. Keep the gun cable as straight as possible when
welding or loading electrode through cable.
3. Do not allow dolly wheels or trucks to run over
cables.
4. Keep cable clean by following maintenance
instructions.
5. Use only clean, rust-free electrode. The Lincoln
electrodes have proper surface lubrication.
6. Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or
deformed.
7. Keep wire reel spindle brake tension to minimum
required to prevent excess reel over-travel which
may cause wire “loop-offs” from coil.
8. Use proper drive rolls and wire drive idle roll pressure for wire size and type being used.
FAN CONTROL
The fan is designed to come on when input power is
applied to the POWER MIG 200 and go off when
power is removed.
INPUT LINE VOLTAGE VARIATIONS
High Line Voltage — Higher than rated input voltage
will result in output voltages higher than normal for a
given tap setting. If your input line is high, you may
want to select a lower voltage tap than given on the
recommended procedure chart.
Low Line Voltage — You may not be able to get
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 200 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.
Steel Thickness Wire Feed Speed/Voltage Tap Settings
Wire Dia. Gas Type WireType
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-
†
Electrical Stickout recommended for a maximun of 5/16"
3/4" ESO
3/8" ESO
†
Polarity 18 gage 16 gage14 gage 12 gage10gage 3/16 1/4 5/16 3/8 1/2
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/B 80/B 90/C 100/C
50/B 70/C 90/C 110/D *130/E
40/B 50/B 60/B 65/C 70/C 90/C 110/D *130/E *150/E *150/E
* Note- Requires Mutiple Pass .035 & .045 NR-211 MP is only
POWER MIG 200
Page 18
C-1
ACCESSORIES
C-1
DRIVE ROLL KITS
Refer to Table C.1 for various drive roll kits that are
available for the POWER MIG 200.The item in Bold is
supplied standard with the POWER MIG 200.
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 200. Each is rated 200 amps 60% duty cycle and
is equipped with the integrated connector, twist-lock
trigger connector, fixed nozzle and insulator, and
includes a liner, diffuser, and contact tips for the wire
sizes specified:
English Wire Metric Wire
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
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.
K363P READI-REEL ADAPTER
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.
SPOOL GUN AND ADAPTER KIT
(K1809-1)
The K1809-1includes the Magnum 250SG Spool gun
and the adapter kit for connecting the spool gun to the
Power MIG 200.
The Adapter Kit provides toggle switch selection
between the machine’s use with its feeder gun or the
spool gun for same polarity welding with different wire
and gas processes.
The kit includes a spool gun adapter module 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 200
before installing the Spool Gun and Kit.
POWER MIG 200
Page 19
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
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
“HOT”.
electrodes electrically
guns to be
C-2C-2
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
“HOT”.
3. Operation with POWER MIG 200:
• Turn the POWER MIG-200 input power ON.
• Adjusting the voltage tap control will increase or
decrease your welding voltage.
• 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.
electrodes electrically
4. Refer to the procedure decal on the Power Mig for
initial aluminum settings. Make a test weld to determine the final settings.
5. To return to normal POWER MIG 200 welding,
release the spool gun trigger set spool gun selector
switch to normal and reset feeder gun voltage procedure setting if necessary.
POWER MIG 200
Page 20
D-1
MAINTENANCE
D-1
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.
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.
• 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.
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.
* 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.
POWER MIG 200
Page 21
D-2
MAINTENANCE
D-2
CAUTION
Excessive pressure at the start may cause the dirt
to form a plug.
Flex the cable over its entire length and again blow
out the cable. Repeat this procedure until no further
dirt comes out. If this has been done and feed problems are experienced, try liner replacement, and refer
to trouble shooting section on rough wire feeding.
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 Adjustable
Nozzle Nozzle
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 M16087-2 .030 (0.8 mm) S19418-3 S19418-2
(0.6-0.8 mm)
.035-.045" Stee M16087-1 .045 (1.2 mm) S19418-3 S19418-1
(0.9-1.2 mm)
3/64" Aluminum M17714-1 3/64" (1.2 mm) S19418-3 S19418-1
(1.2 mm)
LINER REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR
MAGNUM 250L
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 diffusor still removed from the gun
tube, be sure the cable is straight, and then trim
the liner to the length shown in Figure D.1.
Remove any burrs from the end of the liner.
7. Screw the gas diffuser onto the end of the gun tube
and securely tighten. Be sure the gas diffuser is
correct for the liner being used. (See table and 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
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.
POWER MIG 200
CAUTION
This screw should only be gently tightened.
Overtightening will split or collapse the liner and
cause poor wire feeding.
Page 22
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.
D-3
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 M16087-2 .025 – .030" 0.6 – 0.8 mm
shorter Cable M16087-1 .035 – .045" 0.9 – 1.2 mm
M17714-1 3/64" 1.2 mm
(Alum. wire) (Alum. wire)
CONTACT TIPS
Standard Duty S19391-6 .025" 0.6 mm
S19391-7 .030" 0.8 mm
S19391-1 * .035" 0.9 mm
S19391-2 .045" 1.2 mm
Heavy Duty S19392-1 .035" 0.9 mm
S19292-2 .045" 1.2 mm
Tapered S19393-5 .025" 0.6 mm
S19393-6 .030" 0.8 mm
S19393-1 .035" 0.9 mm
S19393-2 .045" 1.2 mm
Tab (For Aluminum) S18697-46 3/64" 1.2 mm
(Alum. Wire) (Alum. Wire)
Counterclockwise
➣
GAS NOZZLES
Fixed (Flush) M16081-1 3/8" 9.5 mm
M16081-2 * 1/2" 12.7 mm
M16081-3 5/8" 15.9 mm
Fixed (Recessed) M16080-1 3/8" 9.5 mm
M16080-2 1/2" 12.7 mm
M16080-3 5/8" 15.9 mm
Requires: Gas
Diffuser As'bly S19418-3 * .025 – .045" 0.6 – 1.2 mm
Adjustable Slip-On M16093-2 1/2" 12.7 mm
M16093-1 5/8" 15.9 mm
Requires:
Nozzle Insulator S19417-1
As’bly
Requires:
Gas Diffuser S19418-2 .025 – .030" 0.6 – 0.8 mm
As’bly S19418-1 .035 – .045" 0.9 – 1.2 mm
Gasless Nozzle M16938 Δ
(For Innershield)
GUN TUBE ASSEMBLIES
Standard (60°) S18920 *
45° S19890
* Included with POWER MIG 200
Δ Requires S19418-1 Gas Diffuser Assembly.
POWER MIG 200
Page 23
E-1
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
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.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER MIG 200
Page 24
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-2E-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 200.
Output voltage and wire feed is present when gun trigger is not pulled
(not activated).
POSSIBLE AREAS OF
MISADJUSTMENT
OUTPUT PROBLEMS
1. Contact your Local Lincoln
Authorized Field Service Facility.
1 The gun trigger or cable may be
faulty. Check or replace gun
assembly.
2. The thermal protection circuit
may be activated. If this is the
case allowing the machine to
cool will clear the error condition.
3. Make sure input voltage is 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 “Normal” 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 200.
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 200
Page 25
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-3
PROBLEMS
(SYMPTOMS)
1. Poor arc striking with electrode
sticking or blasting off.
PROBLEMS
(SYMPTOMS)
1. Rough wire feeding or wire will
not feed but drive rolls are turning.
1. The wire feed stops while welding. When trigger is released
and pulled again the wire feed
starts.
POSSIBLE AREAS OF
MISADJUSTMENT
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 imput line voltage to be
with in machines recommended
rating range.
4. Check that the machine recon-
nect panel is configured properly
for the applied voltage.
FEEDING PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
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.
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.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
1. No control of wire feed speed.
Other machine functions are normal.
1. The wire feed speed control may
be dirty. Rotate several times
and check if problem is resolved.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
POWER MIG 200
Page 26
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-4
PROBLEMS
(SYMPTOMS)
Gas does not flow when gun trigger
is pulled.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
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.
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 200.
5. Make sure the gun is pushed all
the way into gun mount and is
properly seated.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
POWER MIG 200
Page 27
WIRING DIAGRAMS
F-1F-1
CONTROL BOARD
J1
8
1
2
3
102A
101A
103A
ASSEMBLY
RECTIFIER
THERMOSTAT
THERMOSTAT
TRANSFORMER
7
9
6
4
5
107A
109A
108A
106A
105A
104A
104A
104B
103A
104C
131415
SPEED
16
116A
115A
113A
114A
**
1
6
5
432
PA
1
1
J5
116B
104C
116A
108A
JUMPER PLUG
INSTALLED FOR
NON-SPOOL GUN
OPERATION
432
432
6
5
105A
106C
104D
105B
115A
101A
102A
104D
111A
**
5
4
3
2
1
J4
RBU
324
325
4
3
2
1
TRIGGER
GUN
116B
11
10
12
110A
111A
112A
R2
WIRE FEED
113A
109A
J2
1
3
5
2
4
6
105B
112A
6
8
7
B
W
+
B
J3
2
1
L11424
FOR SPOOL GUN OPTION
WORK
TO
MOTOR/
GEARBOX
-
P.M.
W
T
A
C
H
RBU
GAS
SOLENOID
50 W
10-2000
BRIDGE
RECTIF IER
SINGLE PHASE
40 OHMS
CHOKE
R1
OUTPUT
IMMEDIATE AND FUTURE APPLICATIONS.
THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK
STUD.
NOTES:
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF
N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIVE”. TO CHANGE POLARITY, TURN
145
J4 (TRIGGER,
MOTOR SI DE)
TACHOMETER,
B - BLACK
POWER MIG 200 (208/230V)
W - WHITE
** CAVITY
R - RED
U - BLUE
COLOR CODE
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
1
J3
J2
8
INDICATES CONNECTOR CAVITY No.
NUMBERING SEQUENCE
2
613
4
16
PA
(NON-LEAD SIDE OF CONNECTOR)
(COMPONENT SIDE OF P.C. BOARD)
CAVITY NUMBERING SEQUENCE
1
9
J1
107A
8
613
4
106C
106B
G
27.8V
X8
X10
X9
X9
X10
-
114A
+
X9
106A
106B
BRIDGE
DIODE
RECTIFIER
MOUNTED
BAFFLE
F
X7
H1
L2
L1
EDC
X6
X5
H5
L1 L2
H2
H3 H4
CONTACTOR
SWITCH
TAP SELECTOR
A
B
X1
X3
X2
X4
POWER
TRANSFORMER
H2
H3
H1
H4
S1
LINE
SWITCH
H1
208V
PANEL
RECONNECT
230V
G
B
W
TO GROUND PER
SUPPLY LINE
TO SINGLE PHASE
NATIONAL ELECTRICAL
H5H1B
FAN
MOTOR
CODE
+
C2
+
C1
50V
31,000 MFD
C1 AND C2
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..
POWER MIG 200
Page 28
DIMENSION PRINT
3-00F
F-2F-2
M19231
POWER MIG 200
Page 29
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How To Read Shop Drawings
The book contains the latest information and application
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New Lessons in Arc Welding
Lessons, simply written, cover manipulatory techniques;
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528 pages, well illustrated, 6” x 9” size, bound in simulated,
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For details write: Lincoln Welding School
headquarters in Cleveland, Ohio. Over 100,000 stu-
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and ask for bulletin ED-80 or call 216-383-2259 and ask
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Lincoln Welding School
BASIC COURSE $700.00
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Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH
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James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
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(JFLF-515)
New Lessons in Arc Welding $5.00 L
How to Read Shop Drawings $4.50 H
A New Approach to Industrial Economics $5.00 NA
Pipe Welding Charts $4.50 ED-89
SUB TOTAL
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TOTAL COST
Page 30
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Page 31
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Não toque as partes elétricas nuas.
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
Page 32
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