Lincoln Electric SVM157-A User Manual

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POWER MIG

™

200

SERVICE MANUAL

SVM157-A

October 2001

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 machines having Code Numbers:

10564
10584

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• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

Copyright © 2001 Lincoln Global Inc.

POWER MIG 200

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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.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

i

SAFETY

i

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP
CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

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

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

WARNING

Mar ‘95

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

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

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

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

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

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

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

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

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

CALIFORNIA PROPOSITION 65 WARNINGS

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

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

The Above For Diesel Engines

The Above For Gasoline Engines

POWER MIG 200

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ii

SAFETY

ii

ARC RAYS can burn.

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

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

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

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free gloves
to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

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

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

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition.

Replace damaged insulation.

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

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

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

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

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating
products.

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

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

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

5.e. Also see item 1.b.

Mar ‘95

POWER MIG 200

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FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can
cause fire or explosion.

6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent

the welding sparks from starting a fire.

Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

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

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

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

6.h. Also see item 1.c.

POWER MIG 200

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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 l e s
positions assis ou couché pour lesquelles une grande partie
du corps peut être en contact avec la masse.

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

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

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

refroidir.

e. Ne jamais toucher simultanément les parties sous tension des

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

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

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

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

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

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

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

b. Porter des vêtements convenables afin de protéger la peau de

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

c. Protéger l’autre personnel travaillant à proximité au soudage à

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

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

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

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

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

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

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

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

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

117.2-1974.

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

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

vv

POWER MIG 200

MASTER TABLE OF CONTENTS FOR

ALL SECTIONS

Page

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

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

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

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

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

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

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

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

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P372 & P202-H.2

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TABLE OF CONTENTS

- INSTALLATION SECTION -

POWER MIG 200

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

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

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

Uncrating the Power MIG 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

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

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

Dual Voltage Machine Input Connections . . . . . . . . . . . . . . . . . . . . . . . A-4

Triple Voltage Machine Input Connections . . . . . . . . . . . . . . . . . . . . . . A-5

Output Polarity Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Gun and Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Section ASection A

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INSTALLATION

A-2

POWER MIG 200

A-2

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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.)

208/60 60 36 10 (6 mm2) 8 (10 mm2)
230/60 60 33 10 (6 mm2) 8 (10 mm2)

NOTE: Use #10 AWG Grounding Wire

TECHNICAL SPECIFICATIONS – POWER MIG 200

INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES

Height Width Depth Weight

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

PHYSICAL DIMENSIONS

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

WIRE SPEED RANGE

Standard Voltage/Frequency

Input Current @ 150 Amp Rated Output Input Current @ 150 Amp Rated Output

208/230/60 Hz 28/26 Amps 36/33

Duty

Cycle Amps V

olts at Rated Amperes

30% 200 Amps 22 Volts
40% 180 Amps 23 Volts
60% 150 Amps 24 Volts

Welding Current Range

Maximum Open Circuit Voltage Welding Voltage Range

30 – 200 Amps 40 Volts 13.5-22 Volts

INSTALLATION

A-3

POWER MIG 200

A-3

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Read entire installation section before starting
installation.

SAFETY PRECAUTIONS

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.

WARNING

UNCRATING THE POWER MIG 200

Cut banding and lift off cardboard carton. Cut banding
holding the machine to the skid. Remove foam and
corrugated packing material. Untape accessories from
Gas Bottle Platform. Unscrew the two wood screws (at
the Gas Bottle Platform) holding the machine to the
skid. Roll the machine off the skid assembly.

LOCATION

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

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.

WARNING

WARNING

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.

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

INPUT POWER, GROUNDING AND
CONNECTION DIAGRAMS

INSTALLATION

A-4

POWER MIG 200

A-4

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FIGURE A.1 — Dual Voltage Machine Input Connections

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

The 230/460/575 volt 60 Hz model is not equipped
with an input cable or a plug.

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. Agreen
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.

INSTALLATION

A-5

POWER MIG 200

A-5

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FIGURE A.2 — Triple Voltage Machine Input Connections

FIGURE A.3 — Receptacle Diagram

CONNECT TO A SYSTEM
GROUNDING WIRE. SEE
THE UNITED STATES
NATIONALELECTRICAL
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 ATWO 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.

INSTALLATION

A-6

POWER MIG 200

A-6

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.

Turn the welder power switch off before installing
gun and cable.

1. Lay the cable out straight.

2. Unscrew knurled screw on the drive unit front end
(inside wire feed compartment) until tip of screw no
longer protrudes into gun opening as seen from
front of machine.

3. Insert the male end of gun cable into the female
casting through opening in front panel. Make sure
connector is fully inserted and tighten knurled
screw.

4. Connect the gun trigger connector from the gun and
cable to the mating receptacle inside the 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% CO2an additional adapter will

be required to connect the regulator to the gas bottle.

Install shielding gas supply as follows:

1. Set gas cylinder on rear platform of POWER MIG

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

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.

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.

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

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

NOTE: If connecting to 100% CO2cylinder, an
additional regulator adapter must be installed
between the regulator and cylinder valve. If adapter
is equipped with a plastic washer, be sure it is seat­ed for connection to the CO2cylinder.

5. Attach one end of the inlet gas hose to the outlet fit­ting of the flow regulator, the other end to the
POWER MIG 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.

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.

WARNING

WARNING

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TABLE OF CONTENTS

- OPERATION SECTION -

POWER MIG 200

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

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

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

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

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

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

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

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

Wire Size Conversion Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Procedure for Changing Drive and Idle Roll Sets . . . . . . . . . . . . . . . . . B-4

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

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

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

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

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5

Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Input Line Voltage Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Wirefeed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Welding Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

Section BSection B

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OPERATION

B-2B-2

POWER MIG 200

Read entire Operation section before
operating the POWER MIG 200.

ELECTRIC SHOCK can kill.

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

• Always wear dry insulating
gloves.

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

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

WELDING SPARKS can
cause fire or explosion.

• Keep flammable material away.

• Do not weld on closed containers.

ARC RAYS can burn eyes and
skin.

• Wear eye, ear and body protec­tion.

Observe all safety information throughout
this manual.

WARNING

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OPERATION

B-3B-3

POWER MIG 200

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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.

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®; as well as
.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.

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.

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. See Figure
B.1.

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. See Figure B.?.

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. See Figure B.1.

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.

Figure B.1. Control Locations

WIRE FEED SPEED

ON/OFF SWITCH

VOLTAGE

O

N

O

F
F

OPERATION

B-4B-4

POWER MIG 200

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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. Wiggle both the metal idle and drive rolls off of their

plastic hubs.

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,
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.

6. Position the Readi-Reel so that it will rotate in a direction when feed-

ing so as to be de- reeled from top of the coil.

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.

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.2

CAUTION

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: 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.

OPERATION

B-5B-5

POWER MIG 200

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FEEDING WIRE ELECTRODE

When triggering, the electrode and drive mecha­nism are electrically “hot” relative to work and
ground and remain “hot” several seconds after the
gun trigger is released.

NOTE: Check that drive rolls, guide plates and gun

parts are proper for the wire size and type being used.
Refer to Table C.1 in Accessories section.

1. Turn the Readi-Reel or spool until the free end of the
electrode is accessible.

2. While securely holding the electrode, cut off the bent
end and straighten the first six inches. (If the elec­trode is not properly straightened, it may not feed
properly through the wire drive system).

3. Release the pressure on the idle roll by swinging the
adjustable pressure arm down toward the back of
the machine. Lift the cast idle roll assembly and
allow it to sit in an upright position. Leave the outer
wire guide plate installed. Manually feed the wire
through the incoming guide bushing and through the
guide plates (over the drive roll groove). Push a suf­ficient wire length to assure that the wire has fed into
the gun and cable assembly without restriction.
Reposition the adjustable pressure arm to its origi­nal position to apply pressure to the wire.

4. Press gun trigger to feed the electrode wire through
the gun.

IDLE ROLL PRESSURE SETTING

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.

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 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”.

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.

WARNING

WARNING

OPERATION

B-6B-6

POWER MIG 200

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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

Polarity 18 gage16 gage 14 gage 12 gage 10gage 3/16 1/4 5/16 3/8 1/2

Outershield

3/4" ESO

†

.035 75Ar/25CO2OS71M DC+

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

.035 100%CO2OS71M DC+

300/E 350/F 500/G

.045 75Ar/25CO2OS71M DC+

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

Innershield

3/8" ESO

†

.035 NoneReq’d NR-211MP DC-

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

.045 NoneReq’d NR-211MP DC-

50/B 70/C 90/C 110/D *130/E

.045 NoneReq’d NR212 DC-

40/B 50/B 60/B 65/C 70/C 90/C 110/D *130/E *150/E *150/E

* Note- Requires Multiple Pass .035 & .045 NR-211 MP is only

†

Electrical Stickout recommended for a maximum of 5/16"

TABLE B.1.

TABLE OF CONTENTS

- ACCESSORIES SECTION -

POWER MIG 200

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

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

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

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

Dual Cylinder Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

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

Magnum Gun Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Spool Gun and Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

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

Section CSection C

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ACCESSORIES

C-2C-2

POWER MIG 200

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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.

TABLE C.1

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.

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.

Wire Size Drive Roll Kit

.023”-.030” (0.6-0.8 mm)

KP1696-030S

Solid

.035” (0.9 mm) KP1696-035S

Steel

.045” (1.2 mm) KP1696-045S

Cored

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

Aluminum

3/64” (1.2 mm) KP1695-3/64A

ALTERNATIVE MAGNUM GMAW
GUN AND CABLE ASSEMBLIES

The following Magnum 250Lgun 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, dif fuser , and contact tips for the wire sizes spec­ified:

TABLE C.2

MAGNUM GUN CONNECTION KIT
(Optional K466-6)

Using the optional K466-6 Magnum Connection kit for
the POWER MIG permits use of standard Magnum
200, 300 or 400 gun and cable assemblies.

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.

Remove all input power to the POWER MIG 200
before installing the Spool Gun and Kit.

WARNING

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

ACCESSORIES

C-3C-3

POWER MIG 200

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MAKING A WELD WITH THE SPOOL GUN
ADAPTER KIT AND SPOOL GUN
INSTALLED

In either toggle switch position, closing either gun
trigger will cause the electrode of both guns to be
electrically “HOT”. Be sure unused gun is posi­tioned so electrode or tip will not contact metal
case or other metal common to work.

1. Setting spool gun selector switch to the “Normal”
position and pulling the trigger for the built-in feeder
gun.

• Disables spool gun operation and spool gun gas

solenoid valve.

• Closing feeder gun trigger starts feeder gun

welding and makes both electrodes electrically
“HOT”.

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

• Disables built-in feeder gun operation and

machine gas solenoid valve.

• Enables spool gun operation and spool gun gas

solenoid valve.

• Closing spool gun trigger starts spool gun weld-

ing and makes both

electrodes electrically

“HOT”.

3. Operation with POWER MIG 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.

4. Refer to the procedure decal on the Power Mig for
initial aluminum settings. Make a test weld to deter­mine the final settings.

CAUTION

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.

NOTES

C-4C-4

POWER MIG 200

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TABLE OF CONTENTS

- MAINTENANCE SECTION -

POWER MIG 200

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

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

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

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

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

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

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

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

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

Accessories and replacement parts for Magnum

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

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

Section DSection D

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MAINTENANCE

D-2D-2

POWER MIG 200

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SAFETY PRECAUTIONS

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.

(READ THE SAFETY PRECAUTIONS IN
THE FRONT OF THIS MANUAL BEFORE
WORKING ON THIS MACHINE.)

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.

For instructions on replacing or changing drive roll, see
“Wire Drive Rolls” in Operation section.

WARNING

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.

* 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.

MAINTENANCE

D-3D-3

POWER MIG 200

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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 the
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.

CAUTION

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" Steel 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)

TABLE D.1

LINER REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR
MAGNUM 250L

NOTE: The variation in cable lengths prevents the

interchangeability of liners between guns. Once a liner
has been cut for a particular gun, it should not be
installed in another gun unless it can meet the liner cut­off length requirement. Liners are shipped with the
jacket of the liner extended the proper amount.

1. Remove the gas nozzle and nozzle insulator, if
used, to locate the set screw in the gas diffuser
which is used to hold the old liner in place. Loosen
the set screw with a 5/64" (2.0 mm) Allen wrench.

2. Remove the gas diffuser from the gun tube.

3. Lay the gun and cable out straight on a flat surface.
Loosen the set screw located in the brass connec­tor at the feeder end of the cable and pull the liner
out of the cable.

4. Insert a new untrimmed liner into the connector end
of the cable. Be sure the liner bushing is stencilled
appropriately for the wire size bing used.

5. Fully seat the liner bushing into the connector. tight­en the set screw on the brass cable connector. the
gas diffuser, at this time, should not be installed
onto the end of the gun tube.

6. With the gas diffuser still removed from the gun
tube, be sure the cable is straight, and then trim the
liner to the length shown in Figure D.1. Remove any
burrs from the end of the liner.

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

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

CAUTION

SET SCREW

BRASS CABLE CONNECTOR

SET SCREW

GAS DIFFUSER

NOZZLE INSULATOR (IF USED)

GAS NOZZLE

1-1/4"

(31.8mm)

LINER

TRIM

LENGTH

MAINTENANCE

D-4D-4

POWER MIG 200

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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

➣

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)

CONTACTTIPS
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)

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 ∆

(For Innershield)

GUN TUBE ASSEMBLIES

Standard (60°) S18920 *
45° S19890

TABLE D.2

ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS

FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES

* Included with POWER MIG 200
∆ Requires S19418-1 Gas Diffuser Assembly.

MAINTENANCE

D-5D-5

POWER MIG 200

1. Case Front Assembly

2. Rear Panel Assembly

3. Center Assembly

4. Wire Drive Assembly

5. Base & Power Component
Assembly

6. Covers Assembly

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6

1

2

3

4

5

NOTES

D-6D-6

POWER MIG 200

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TABLE OF CONTENTS

- THEORY OF OPERATION SECTION -

POWER MIG 200

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

Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Voltage Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Baffle Mounted Diode Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

Output Rectification, Contactor & Control Boards . . . . . . . . . . . . . . E-3

Optional Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Control Board, Gun Trigger, & Wire Drive Motor . . . . . . . . . . . . . . . E-4

Protective Devices & Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Wirefeed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5

Section ESection E

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FIGURE E.1 THEORY OF OPERATION BLOCK DIAGRAM

LINE
SWITCH

FAN
MOTOR

RECONNECT
PANEL

RECTIFIER
DIODE
BRIDGE

28 VAC

MAIN
TRANSFORMER

GAS
SOLENOID

TAP SELECTOR
SWITCH

CONTROL BOARD

CONTACTOR

CONTACTOR

CONTROL

WIRE
SPEED
CONTROL

OUTPUT DIODE
BRIDGE

FEEDBACK

GUN TRIGGER

+

-

WIRE
DRIVE
MOTOR

TACH

OUTPUT
CHOKE

OUTPUT
CAPACITORS

TRANSFORMER
THERMOSTAT

POSITIVE
TERMINAL

NEGATIVE
TERMINAL

OUTPUT BRIDGE
THERMOSTAT

+

-

GUN
ASSEMBLY

THEORY OF OPERATION

E-2E-2

POWER MIG 200

FIGURE E.2 – INPUT POWER CIRCUIT.

INPUT LINE VOLTAGE, MAIN
TRANSFORMER, VOLTAGE
SELECTOR SWITCH AND
BAFFLE MOUNTED DIODE
BRIDGE

The single phase input power is connected to
the POWER MIG 200 through a line switch
located on the front panel.

A reconnect panel allows the user to configure
the machine for the desired input voltage. The
AC input voltage is applied to the primary of the
main transformer. The cooling fan motor
(120VAC) is powered from a portion of the
primary winding. For welding purposes, the
main transformer converts the high voltage, low
current input power to a lower voltage, higher
current output. This tapped secondary winding
is coupled to a voltage selector switch. By
selecting one of seven positions on the switch
the user can preset the desired voltage output

from a minimum setting (A) to a maximum
voltage setting (G). In addition, the main
transformer houses a 28VAC winding. This
28VAC is rectified at the baffle mounted diode
bridge and the resultant DC voltage is used to
power the electronics on the control board, the
output contactor, and the gas solenoid.

NOTE: Unshaded areas of block logic diagrams are the subject of discussion.

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GAS
SOLENOID

CONTROL BOARD

LINE
SWITCH

FAN
MOTOR

RECONNECT
PANEL

RECTIFIER
DIODE
BRIDGE

28 VAC

MAIN
TRANSFORMER

TAP SELECTOR
SWITCH

CONTACTOR

WIRE
SPEED
CONTROL

WIRE
DRIVE
MOTOR

CONTACTOR

CONTROL

OUTPUT DIODE
BRIDGE

+

-

FEEDBACK

GUN TRIGGER

OUTPUT
CAPACITORS

TACH

OUTPUT
CHOKE

TRANSFORMER
THERMOSTAT

OUTPUT BRIDGE
THERMOSTAT

+

POSITIVE
TERMINAL

-

NEGATIVE
TERMINAL

GUN
ASSEMBLY

THEORY OF OPERATION

E-3E-3

POWER MIG 200

OUTPUT RECTIFICATION,
CONTACTOR AND CONTROL
BOARD

The AC voltage developed on the secondary
winding is applied, through the selector switch
and output contactor, to the output rectifier
bridge. This DC welding voltage is filtered by
the output capacitors and applied to the output
terminals and welding gun. Since the output
choke is in series with the positive leg of the
output rectifier and also in series with the gun
and welding load, a filtered constant voltage
output is applied to the output terminals of the
machine.

FIGURE E.3 – CONTROL CIRCUITS.

NOTE: Unshaded areas of block logic diagrams are the subject of discussion.

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GAS
SOLENOID

LINE
SWITCH

FAN
MOTOR

RECONNECT
PANEL

RECTIFIER
DIODE
BRIDGE

28 VAC

MAIN
TRANSFORMER

TAP SELECTOR
SWITCH

CONTROL BOARD

CONTACTOR

CONTACTOR

CONTROL

WIRE
SPEED
CONTROL

OUTPUT DIODE
BRIDGE

FEEDBACK

GUN TRIGGER

+

-

WIRE
DRIVE
MOTOR

TACH

OUTPUT
CHOKE

OUTPUT
CAPACITORS

TRANSFORMER
THERMOSTAT

POSITIVE
TERMINAL

NEGATIVE
TERMINAL

OUTPUT BRIDGE
THERMOSTAT

+

-

GUN
ASSEMBLY

THEORY OF OPERATION

E-4E-4

POWER MIG 200

CONTROL BOARD, GUN
TRIGGER AND WIRE DRIVE
MOTOR

When the control board receives an activation
command from the trigger circuit the control
board activates the gas solenoid, output
contactor, and the wire drive motor. The control
board monitors the motor’s tach feedback
signals and compares these to the wire speed
control setting. The proper armature voltage is
then applied to the wire drive motor. The drive
motor speed is thus controlled which in turn
regulates the electrode wire feed speed through
the gun.

Two thermostats are included in the trigger
circuitry. If either of these thermostats would
“open”, the trigger circuit would be interrupted
and the machine’s output would be disabled.

FIGURE E.4 – OPTIONAL CIRCUITS.

NOTE: Unshaded areas of block logic diagrams are the subject of discussion.

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GAS
SOLENOID

CONTROL BOARD

LINE
SWITCH

FAN
MOTOR

RECONNECT
PANEL

RECTIFIER
DIODE
BRIDGE

28 VAC

MAIN
TRANSFORMER

TAP SELECTOR
SWITCH

CONTACTOR

CONTACTOR

WIRE
SPEED
CONTROL

OUTPUT DIODE

CONTROL

BRIDGE

FEEDBACK

GUN TRIGGER

+

-

WIRE
DRIVE
MOTOR

TACH

OUTPUT
CHOKE

OUTPUT
CAPACITORS

TRANSFORMER
THERMOSTAT

NEGATIVE
TERMINAL

OUTPUT BRIDGE
THERMOSTAT

+

POSITIVE
TERMINAL

-

GUN
ASSEMBLY

THEORY OF OPERATION

E-5E-5

POWER MIG 200

PROTECTIVE DEVICES AND CIRCUITS

THERMAL AND OVERLOAD PROTECTION

The POWER MIG 200 has two built-in protective
thermostats that respond to excessive temperatures.
One is located on the main transformer. The other
thermostat is located on the output rectifier heat sink
assembly. They open the wire feed and welder
output circuits if the machine exceeds the maximum
safe operating temperature. This can be caused by
a frequent overload or high ambient temperature.

The thermostats are self-resetting once the machine
cools sufficiently. If the thermostat shutdown is caused
by excessive output or duty cycle and the fan is
operating normally, the power switch may be left on
and the reset should occur within a 15 minute period.
If the fan is not turning or the air intake louver are
obstructed, then the input power must be removed
and the fan problem or air obstruction must be
corrected.

WIREFEED OVERLOAD PROTECTION

The POWER MIG 200 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, drive rolls, and any obstructions
or bends in the gun cable. Check for 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.

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NOTES

E-6E-6

POWER MIG 200

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TABLE OF CONTENTS

- TROUBLESHOOTING AND REPAIR SECTION -

POWER MIG 200

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

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11

Main Transformer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-11

Wire Drive Motor and Tachometer Feedback Test . . . . . . . . . . . . . . F-15

Output Bridge Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-19

Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-21

Voltage Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-23

Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . F-27

Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-27

Wire Drive Motor Assembly Replacement . . . . . . . . . . . . . . . . . . . . F-29

Output Diode Bridge Rectifier Replacement . . . . . . . . . . . . . . . . . . F-33

Output Capacitors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . F-37

Main Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . F-41

Fan Blade/Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-47

Output Contactor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . F-49

Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-52

Section FSection F

WARNING

ELECTRIC SHOCK can kill.

• Never work on the inside of the machine without removing the
input power. You can receive a life threatening electrical shock if
you fail to do this. Only qualified technicians should perform
installation, maintenance, and troubleshooting work on the
machine.

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F-2

TROUBLESHOOTING AND REPAIR

F-2

POWER MIG 200

If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical
troubleshooting assistance before you proceed. Call 1-800-833-9353.

Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger
to the technician and machine operator and will invalidate your factory warranty. For
your safety and to avoid Electrical Shock, please observe all safety notes and
precautions detailed throughout this manual.

This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three step
procedure below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes
possible symptoms that the machinery may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Symptoms are grouped according to:
feeding problems and function problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may
contribute to the machine symptom.
Perform these tests/checks in the order
listed. In general, these tests can be
conducted without removing the case wrap­around cover.

Step 3. PERFORM COMPONENT TESTS.

The last column labeled “RECOMMENDED
COURSE OF ACTION” lists the most likely
components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject
component is either bad or good. If there
are a number of possible components,
check the components in the order listed

to
eliminate one possibility at a time until you
locate the cause of your problem.

All the necessary test specifications and
repair procedures are described in detail
following the troubleshooting guide. All
electrical test points, terminal strips,
junctions, etc., can be found on the
electrical wiring diagrams and schematics
in the Electrical Diagram Section.

WARNING

CAUTION

How To Use Troubleshooting Guide

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F-3

TROUBLESHOOTING AND REPAIR

F-3

POWER MIG 200

Sometimes machine failures appear to be due
to PC board failures. These problems can
sometimes be traced to poor electrical con­nections. To avoid problems when trou­bleshooting and replacing PC boards, please
use the following procedure:

1. Determine to the best of your technical
ability that the PC board is the most
likely component causing the failure
symptom.

2. Check for loose connections at the PC
board to assure that the PC board is
properly connected.

3. If the problem persists, replace the
suspect PC board using standard
practices to avoid static electrical
damage and electrical shock. Read the
warning inside the static resistant bag
and perform the following procedures:

PC board can be
damaged by static
electricity.

- Remove your body’s
static charge before
opening the static­shielding bag. Wear an
anti-static wrist strap. For
safety, use a 1 Meg ohm
resistive cord connected
to a grounded part of the
equipment frame.

- If you don’t have a wrist

strap, touch an un­painted, grounded, part of the equipment
frame. Keep touching the frame to prevent
static build-up. Be sure not to touch any
electrically live parts at the same time.

ELECTRIC SHOCK
can kill.

•

Have an electrician
install and service this
equipment. Turn the input
power OFF at the

- Tools which come in contact with the PC
board must be either conductive, anti-static or
static-dissipative.

- Remove the PC board from the static-shield­ing bag and place it directly into the equip­ment. Don’t set the PC board on or near paper,
plastic or cloth which could have a static
charge. If the PC board can’t be installed
immediately, put it back in the static-shielding
bag.

- If the PC board uses protective shorting
jumpers, don’t remove them until installation is
complete.

- If you return a PC board to The Lincoln
Electric Company for credit, it must be in the
static-shielding bag. This will prevent further
damage and allow proper failure analysis.

4. Test the machine to determine if the
failure symptom has been corrected by
the replacement PC board.

NOTE: It is desirable to have a spare
(known good) PC board available for PC
board troubleshooting.

NOTE

: Allow the machine to heat up so that

all electrical components can reach their
operating temperature.

5. Remove the replacement PC board and
substitute it with the original PC board
to recreate the original problem.

a. If the original problem does not

reappear by substituting the original
board, then the PC board was not
the problem. Continue to look for
bad connections in the control wiring
harness, junction blocks, and
terminal strips.

b. If the original problem is recreated by

the substitution of the original board,
then the PC board was the problem.
Reinstall the replacement PC board
and test the machine.

6. Always indicate that this procedure was
followed when warranty reports are to
be submitted.

NOTE

: Following this procedure and writing

on the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY PROB­LEM,” will help avoid denial of legitimate PC
board warranty claims.

PC BOARD TROUBLESHOOTING PROCEDURES

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

WARNING

CAUTION

fuse box before working on equipment. Do
not touch electrically hot parts.

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OUTPUT PROBLEMS

Observe Safety Guidelines

detailed in the beginning of this manual.

Troubleshooting Guide – See Wiring Diagrams for location of specified

components and for troubleshooting of specific circuits.

F-4

TROUBLESHOOTING AND REPAIR

F-4

POWER MIG 200

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-800-833-9353.

CAUTION

Major physical or electrical damage is evident.

1.Contact your local Lincoln
Electric authorized field service
facility.

1.Contact Lincoln Electric
Service Department 1-800­833-9353 (WELD).

The machine is dead--no open
circuit voltage and no wire feed
when the gun trigger is activated.
The cooling fan is not running.

1. Make certain the input power
switch (S1) is in the “ON”
position.

2. Check the input voltage at the
machine. The input voltage
must match the rating plate and
the reconnect panel.

3. Check for blown or missing
fuses in the input lines.

1. Check the input power switch
(S1). It may be faulty.

2. Check for broken or missing
wires at the reconnect panel.

3. Perform the Main Transformer

Test.

There is no open circuit voltage
or wire feed when the gun trigger
is activated. The cooling fan is
running.

1. Make sure the input voltage is
correct and matches the
nameplate rating and reconnect
panel configuration.

2. One of the two thermostats may
be open due to machine
overheating. If the machine
operates normally after a
cooling off period then check for
proper fan operation and
ventilation. Make certain the
machine’s duty cycle is not
being exceeded.

1. The baffle mounted rectifier
bridge may be faulty. Check
and replace if necessary.

2. Perform the Main Transformer

Test.

3. Check the thermostats and

associated leads for loose or
faulty connections. See the
wiring diagram.

4. The internal triggering

circuit/plugs may be faulty. See
the wiring diagram.

5. The control board may be faulty.

When the gun trigger is activated and the wire feeds normally, but there is no open circuit voltage.

OUTPUT PROBLEMS (Continued)

TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines

detailed in the beginning of this manual.

Troubleshooting Guide – See Wiring Diagrams for location of specified

components and for troubleshooting of specific circuits.

F-5F-5

POWER MIG 200

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

(continued from previous page) 3. Check the gun trigger leads.

Leads #324 to #325 should
have continuity (zero ohms)
when the gun trigger is activat­ed. If not, the gun trigger or
cable may be faulty. Check or
replace.

4. If a spool gum option kit is
installed, check to make sure it
is set to the “normal” position if
using the POWER MIG 200 built
in wire feeder.

1. Make sure the gun cable and
work cables are connected
properly and in good condition.

2. Make sure the output selector
switch is in a good condition
position and not between posi­tions.

1. Check the output selector
switch for proper operation and
good connections.

2. Perform the Output Contactor

Test.

3. Perform the Output Bridge
Rectifier Test.

4. Perform the Main Transformer
Test.

5. Check the heavy current carry­ing leads between the output
selector switch, output contac­tor, output bridge rectifier, and
the output terminals for loose or
faulty connections. See Wiring
Diagram.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-800-833-9353.

CAUTION

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OUTPUT PROBLEMS (Continued)

Observe Safety Guidelines

detailed in the beginning of this manual.

Troubleshooting Guide – See Wiring Diagrams for location of specified

components and for troubleshooting of specific circuits.

The machines output is low. W elds
are “cold”. The weld beads are
rounded or “humped” demonstrat­ing poor wetting into the plate. The
machine cannot obtain full rated
output of 200 amps at 22VDC.

1. Check the input voltage. Make
sure the machine is configured
properly for the input voltage
being applied.

2. Make sure the settings for wire
feed speed and voltage are cor­rect for the process being used.

3. Make sure the electrode polarity
is correct for the process being
used.

4. Check the welding cables and
gun for loose or faulty connec­tions.

1. Check for loose or faulty con­nections on the heavy current
carrying leads inside the
POWER MIG 200. See the
Wiring Diagram.

2. The output capacitors may be
faulty. Check for loose connec­tions at the capacitors. Also
check for leaky capacitors.
Replace if necessary.

WARNING: The liquid electrolyte
in these capacitors is toxic.
Avoid contact with any portion of
your body.

3. The output selector switch may
be faulty. Check for good con­tact and continuity (zero ohms)
through the switch. See the
Wiring Diagram.

4. Perform the Output Contactor

Test.

5. Perform the Output Bridge
Rectifier Test.

6. Perform the Main Transformer
Test.

F-6

TROUBLESHOOTING AND REPAIR

F-6

POWER MIG 200

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

Output voltage and wire feed speed is present when the gun trigger is NOT activated.

1. Remove the gun assembly. If
the problem is resolved, the gun
assembly is faulty. Repair or
replace. If the problem is NOT
resolved, the fault is within the
POWER MIG 200 machine.

1. Check for “shorts” in the trigger
circuitry within the POWER MIG
200 machine. See the wiring
diagram.

2. The control board may be faulty .

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-800-833-9353.

CAUTION

The output voltage is continuous
when the gun trigger is NOT activat­ed. The wire feed functions normal­ly.

1. The output contactor may be
stuck closed.

1. Perform the Output Contactor

Test.

TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines

detailed in the beginning of this manual.

Troubleshooting Guide – See Wiring Diagrams for location of specified

components and for troubleshooting of specific circuits.

F-7F-7

POWER MIG 200

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the

Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353

CAUTION

FUNCTION PROBLEMS

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

There is no gas flow when the gun trigger is activated . The wire feeds and the arc voltage is present.

The machine stops feeding wire
while welding. When the gun trig­ger is released and pulled again,
the wire feed starts.

1. If a spool gun adapter is installed,
make certain the toggle switch in
the spool gun kit in the correct
position.

2. If a spool gun adapter is NOT
installed, make certain the jumper
plug is installed in J5. See the
wiring diagram.

3. Check the gas source and hoses
for kinks or leaks.

1. Check for a mechanical restric­tion in the wire feed path. The
gun may be clogged.

2. Make sure the drive rolls and
guide plates are clean and are
the correct size.

3. Check the spindle for ease of
rotation.

1. Check plug J1 on the control board
for loose or faulty connections. See
wiring diagram.

2. Check the gas solenoid by discon­necting it from leads #108A and
#116A&B. Apply a 12VDC external
supply to the solenoid. If the sole­noid does NOT activate then it may
be faulty. Replace.

1. Check the motor armature current.
Normal armature current is 2.0 to 2.7
amps maximum. If the motor arma­ture current is normal, and the motor
continues to shut-off, the control
board may be faulty. Replace.

2. If the motor armature current is high
(over 2.7 amps) and there are NO
restrictions in the wire feeding path
then the motor or gearbox may be
defective. Replace.

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TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines

detailed in the beginning of this manual.

Troubleshooting Guide – See Wiring Diagrams for location of specified

components and for troubleshooting of specific circuits.

F-8F-8

POWER MIG 200

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the

Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353

CAUTION

WIRE FEEDING PROBLEMS

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

No control of wire feed speed.
Other machine functions are nor­mal.

There is no wire feed when the gun
trigger is activated. Normal open
circuit weld voltage is present and
the gas solenoid functions normally.

1. The wire feed speed control may
be dirty . Rotate several times and
check if the problem is resolved.

1. Check for adequate wire supply.

2. If the drive rolls are turning, check
for a mechanical restriction in the
wire feed path.

3. The gun liner may be clogged.
Check or replace.

4. If the drive rolls are not turning
when the gun trigger is activated,
contact your local Lincoln Electric
Authorized Field Service Facility.

1. The wire speed control potentiometer
may be faulty. Check or replace.
Normal potentiometer resistance is
10K ohms.

2. Perform the Wire Drive Motor and

Tachometer Feedback Test.

3. The control board may be faulty.

1. Perform the Wire Drive Motor and

Tachometer Feedback Test.

2. The wire speed control potentiometer
may be faulty. Check or replace.
Normal potentiometer resistance is
10K ohms.

3. The control board may be faulty.

Rough wire feeding or the wire will
not feed but the drive rolls are turn­ing.

1. The gun cable may be kinked or
twisted.

2. Check the drive roll tension and
the position of the grooves.

3. Electrode may be rusted or dirty.

4. The contact tip may be damaged
or not the correct size.

5. Check the wire spindle for ease of
rotation.

6. Make certain the gun is pushed all
the way into the gun mount and
properly seated.

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TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines

detailed in the beginning of this manual.

Troubleshooting Guide – See Wiring Diagrams for location of specified

components and for troubleshooting of specific circuits.

F-9F-9

POWER MIG 200

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the

Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353

CAUTION

WELDING PROBLEMS

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

Poor arc striking with electrode sticking or blasting off.

The arc is unstable and or “hunting”

1. Make sure the settings for wire

feed speed and voltage are cor­rect for the process being used.

2. Make certain the gas shielding is

correct for the process being
used.

3. Make sure the machine’s recon-

nect panel is configured properly
for the input voltage being
applied.

1. Check for a worn or melted con-

tact tip.

2. Check for loose or faulty connec-

tions on the work and gun cables.

3. Make sure the electrode polarity

is correct for the welding process
being used.

4. Check for rusted or dirty electrode

wire.

5. Make sure the machine’s settings

and shielding gas are correct for
the process being used .

1. The output capacitors may be faulty.
Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.

WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid con­tact with any portion of your body.

2. Perform the Output Diode Rectifier
Test.

1. Check for loose or faulty connections
at the output terminals, choke, output
capacitors, output selector switch,
output contactor, and all heavy cur­rent carrying leads. See the wiring
diagram.

2. Check the output selector switch for
proper operation and good connec­tions.

3. The output capacitors may be faulty.
Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.

WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid con­tact with any portion of your body.

4. Perform the Output Bridge Rectifier
Test.

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TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines

detailed in the beginning of this manual.

Troubleshooting Guide – See Wiring Diagrams for location of specified

components and for troubleshooting of specific circuits.

F-10F-10

POWER MIG 200

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the

Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353

CAUTION

WELDING PROBLEMS

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

The weld bead is narrow or ropy.
May have porosity with the elec­trode stubbing into the plate.

The contact tip seizes in the gas dif­fuser.

1. Make sure the welding proce­dures and electrode polarity are
correct for the process being
used.

2. Make certain the shielding gas is
correct and the flow is proper.

3. Make sure the weld joint is not
“contaminated”.

1. The tip is being over heated due
to excessive current and/or high
duty cycle.

2. Alight application of high temper­ature anti-seize lubricant may be
applied to the contact tip threads.

1. Perform the Output Bridge Rectifier
Test.

2. The output capacitors may be faulty.
Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.

WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid con­tact with any portion of your body.

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TROUBLESHOOTING AND REPAIR

F-11F-11

POWER MIG 200

TEST DESCRIPTION

This test will determine if the correct voltages are being applied.
a. Applied to the primary windings of the main transformers.
b. Induced on the secondary and auxiliary windings of the main transformer.

MATERIALS NEEDED

3/8” Nutdriver
5/16” Nutdriver
Volt-ohmmeter

MAIN TRANSFORMER TEST

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

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This procedure takes approximately 40 minutes to perform.

TEST PROCEDURE

THE ON/OFF POWER SWITCH will be
“hot” during these tests.

NOTE: Secondary voltages will vary

proportionately with the primary input
voltage.

1. Disconnect the main input power
supply to the machine.

2. Remove the case top and side panels
with a 3/8” nutdriver.

3. Remove the tool tray with a 5/16” nut
driver.

4. Locate leads X2 thru X8 located on
the output selector switch. See Figure
F.1.

5. Locate lead X1 located on the output
rectifier assembly. See Figure F.2.

6. Locate leads X9 and X10. See Figure

F.3.

7. Connect main input power to the
machine.

8. Turn the POWER MIG 200 ON/OFF
Power Switch to the ON position.

9. Carefully make the following voltage
tests. See Table F.1.

10. Turn Off the machine.

11. If any of the voltages are incorrect

or missing, check for loose or broken
connections between the main
transformer and the test points.

TROUBLESHOOTING AND REPAIR

F-12F-12

POWER MIG 200

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MAIN TRANSFORMER TEST (continued)

FIGURE F.1. – OUTPUT SELECTOR SWITCH TERMINALS

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.

WARNING

X2

X3

X5X4

X6

X7

X8

F-13

TROUBLESHOOTING AND REPAIR

F-13

POWER MIG 200

MAIN TRANSFORMER TEST (continued)

FIGURE F.2. – LEAD X1

FIGURE F.3. – LEAD X9 & X10

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X1

X9

X10

TROUBLESHOOTING AND REPAIR

F-14F-14

POWER MIG 200

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INPUT VOLTAGE TEST POINTS

EXPECTED VOLTAGE READING

11.9-13.0 VAC

14.1-15.2 VAC

16.2-17.5 VAC

18.4-19.7 VAC

20.5-22.0 VAC

22.7-24.2 VAC

24.8-26.5 VAC

26.9-28.8 VAC

X1-X2
X1-X3
X1-X4
X1-X5
X1-X6
X1-X7
X1-X8

X9-X10

230 VAC
230 VAC

230 VAC
230 VAC
230 VAC
230 VAC
230 VAC
230 VAC

TABLE F.1. Test Points

12. If ALLthe voltages tested are incorrect
or missing, test for correct nameplate
input voltage between the H1 lead at the
ON/OFF POWER SWITCH to H2 or H3
at the reconnect panel. Voltage tested
will vary depending on input voltage con­nection. See wiring diagram for test
point locations.

A. If the input voltage test is incorrect,

check for loose or broken leads between
the reconnect panel and the ON/OFF
POWER SWITCH.

B. Test the ON/OFF POWER SWITCH for

proper operation.

13. If the correct nameplate voltage is being
applied to the main transformer and one
or more of the secondary voltages are
missing or are incorrect, the main trans­former may be faulty. Replace.

14. When test is complete, replace tool tray,
case sides and top.

TROUBLESHOOTING AND REPAIR

F-15F-15

POWER MIG 200

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST

WARNING

This procedure takes approximately 30 minutes to perform.

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

TEST DESCRIPTION

This test will determine if the wire drive motor and voltage feedback circuit are functioning
properly.

MATERIALS NEEDED

5/16” Nutdriver
Volt-Ohmmeter

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TROUBLESHOOTING AND REPAIR

F-16F-16

POWER MIG 200

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WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST

(continued)

FIGURE F.4. – PLUG J4

TEST PROCEDURE

NOTE: POLARITY MUST BE OBSERVED

FOR THESE TESTS.

Test for correct wire drive motor armature
voltage.

1. Disconnect main input power to the
machine.

2. Open the side panels and remove the
tool tray using a 5/16” nutdriver.

3. Locate plug J4 on the wiring harness.
See Wiring Diagram.

4. Locate the black and white armature
leads on plug J4. See Figure F.4.

Black
Tach

Black
Arm

J11

Red
Tach

White
Arm

Blue
Tach

TROUBLESHOOTING AND REPAIR

F-17F-17

POWER MIG 200

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST

(continued)

5. Make the following voltage tests:

a. Turn the machine OFF between each

test.

b. Carefully insert the meter probes into

the lead side of plug J4. See Figure

F.4.

c. Turn the machine ON and pull the gun

trigger to conduct the voltage test.

6. If the voltage to the wire drive motor arma­ture is zero, check the wires between plug
J4 and the wire drive motor. Also check
the electrical connector J5 for proper con­nections and jumper plug. See the Wiring
Diagram.

7. If all wires and connectors are good and
the voltage to the drive motor armature is
zero, the control PC board may be faulty.
Replace the control PC board.

8. If the motor is running at high speed and
the armature voltage is high and uncon­trollable, Proceed with the tachometer test.

TEST FOR SUPPLY VOLTAGE TO
TACHOMETER

1. Disconnect the main AC input power to the
machine.

2. Locate plug J4.

3. Locate the tach leads on plug J4. See

Figure F.5.

4. Connect the main input power to the
machine.

5. Make the following voltage tests:

a. Turn the machine OFF between each test.
b. Carefully insert the meter probes into the

lead side of plug J4.

6. If the 5-6 VDC is present, check the leads
to the tachometer circuit.

7. If the leads are okay and 5-6 VDC is pre­sent, the correct voltage is being received
from the control PC board. Continue with
the supply voltage to tachometer test.

8. If the 5-6 VDC is not present and the leads
are okay, the control PC board may be
faulty, replace the control PC board. Also
check plug J5 and the jumper plug. See
Wiring Diagram.

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.

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.

WARNING

FROM LEAD

FROM LEAD

FROM LEAD

Black
Armature
Lead

White
Armature
Lead

2-29 VDC

(varies depend­ing on wire feed
speed)

FROM LEAD

FROM LEAD

FROM LEAD

Black (-)

Red (+) 5-6 VDC

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TROUBLESHOOTING AND REPAIR

F-18F-18

POWER MIG 200

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WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST

(continued)

TEST FOR FEEDBACK VOLTAGE
TO CONTROL BOARD

1. Disconnect the main AC input power to
the machine.

2. Locate plug J4 and the tach leads.
See Figure F.5.

3. Connect main input power to the
machine.

4. Make the following voltage tests:

a. Turn the machine OFF between

each test.

b. Carefully insert the meter probes

into the lead side of plug J4. See
Figure F5.

c. Turn the machine ON and pull the

gun trigger to conduct the voltage
test.

5. If the 3.0 to 4.0 VDC is present, the
tachometer circuit is sending the correct
feedback signal to the control PC board.
Check the leads and plug J5. See the
Wiring Diagram.

6. If the 3.0 to 4.0 VDC is NOT present
or NOT correct, the control PC board
is not receiving the proper feedback
voltage from the tachometer circuit.

7. If the leads are okay, the tachometer
circuit may be faulty, replace the
tachometer circuit.

8. Replace the tool tray.

FROM LEAD

TO LEAD

EXPECTED

VOLTAGE

Black (-)

BLUE (+)

3.0 TO 4.0
VDC

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.

WARNING

FIGURE F.5. – PLUG J4

Black
Tach

Black
Arm

White
Arm

J11

Red
Tach

Blue
Tach

TROUBLESHOOTING AND REPAIR

F-19F-19

POWER MIG 200

OUTPUT BRIDGE RECTIFIER TEST

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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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

This procedure takes approximately 20 minutes to perform.

TEST DESCRIPTION

This test will determine if a diode is “shorted” or “leaky”. See the machine waveform
section in this manual for normal and abnormal output wave forms.

MATERIALS NEEDED

Analog Volt-ohmmeter or Diode Tester
3/8” Nutdriver
1/2” Nutdriver

TROUBLESHOOTING AND REPAIR

F-20F-20

POWER MIG 200

OUTPUT BRIDGE RECTIFIER TEST (continued)

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TEST PROCEDURE

1. Remove input power to the POWER
MIG 200 machine.

2. Using the 3/8” nutdriver, remove the left
case side.

3. Locate and disconnect the negative lead
from the output rectifier bridge assembly.
Be sure there is no electrical contact
between the rectifier and the lead. See
Figure F.6.

NOTE: Do not disassemble the rectifier

assembly.

4. Test for “shorted” or “leaky” diodes by
checking from the anodes to the cathodes
of the diode heatsink plates. The
readings should be high resistance in
one polarity and low resistance in the
opposite polarity.

5. If any of the diodes are “leaky” or
“shorted” the output rectifier assembly
should be replaced.

6. When the test is complete, replace the
negative output lead previously removed.

7. Replace the left case side.

Figure F.6. Rectifier Test Points

Front

+

-

Negative Lead

TROUBLESHOOTING AND REPAIR

F-21F-21

POWER MIG 200

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

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This procedure takes approximately 30 minutes to perform.

CONTACTOR TEST

TEST DESCRIPTION

This test will determine if the contactor is functional.

MATERIALS NEEDED

12 VDC Supply

Volt/Ohmmeter

7/16” Wrench

TROUBLESHOOTING AND REPAIR

F-22F-22

POWER MIG 200

TEST PROCEDURE

1. Remove the input power to the POWER
MIG 200 machine.

2. Using the 5/16” Nutdriver, remove the
tool tray.

3. Locate and remove leads 106B, 106C
and 107A from the contactor coil
terminals. See Figure F.7. See the
Wiring Diagram.

4. Using the 7/16” wrench, remove one
lead from the contactors large terminals.
See Figure F.7. See the Wiring Diagram.

5. Carefully apply 12 VDC to the contactor
coil leads. (small terminals)

Do not leave the 12 VDC applied to the
contactor coil for a prolonged period of
time (15 seconds maximum). Damage
to contactor may result.

6. If the contactor does not activate when
the 12VDC is applied, the contactor is
faulty. Replace.

7. If the contactor activates when the
12VDC is applied, check the resistance
between the two large terminals with
the contactor activated. The resistance
should be very low (0 to 1 ohm).

8. If the resistance is “high” or “open”
between the two large terminals when
the contactor is activated, the contactor
is faulty. Replace.

9. If the contactor activates and the
resistance between the terminals is low
when the 12 VDC is applied, the
contactor is good

NOTE: When the contactor is not activated,

the resistance between the
terminals should be very high
(infinite). If the resistance is always
low, the contacts are “stuck” and
the contactor is faulty. Replace.

10. When the test is complete, replace

leads 106B, 106C and 107A.

11. Replace the lead previously removed

from one of the contactor large
terminals.

12. Replace the tool tray.

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Figure F.7. Contactor Terminals and Leads

CAUTION

CONTACTOR TEST (Continued)

106B

106C

107A

Output
Contactor

TROUBLESHOOTING AND REPAIR

F-23F-23

POWER MIG 200

TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

(MAX TAP “G”)

10.0 V 5 ms

0 Volts

This is a typical DC output voltage wave­form generated from a properly operat­ing machine. Note that each vertical
division represents 10 volts and that
each horizontal division represents 5
milliseconds in time. The machine was
loaded with a resistance grid bank.

NOTE: Scope probes connected at

machine output terminals: (+)
probe to electrode, (-) probe to
work.

Volts/Div.................................10V/Div

Horizontal Sweep.................5 ms/Div

Coupling........................................DC

Trigger....................................Internal

SCOPE SETTINGS

MACHINE LOADED TO 200 AMPS AT 22 VDC

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TROUBLESHOOTING AND REPAIR

F-24F-24

POWER MIG 200

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NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”)

20.0 V 1.0 ms

0 Volts

This is a typical DC output voltage wave­form generated from a properly operat­ing machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 1.0
milliseconds in time.

NOTE: Scope probes connected at

machine output terminals: (+)
probe to electrode, (-) probe to
work.

Volts/Div.................................20V/Div

Horizontal Sweep..............1.0 ms/Div

Coupling........................................DC

Trigger....................................Internal

SCOPE SETTINGS

TROUBLESHOOTING AND REPAIR

F-25F-25

POWER MIG 200

ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE

LOADED (MAX TAP “G”)

ONE OUTPUT DIODE NOT FUNCTIONING

20.0 V 5 ms

0 Volts

This is NOT a typical DC output voltage
waveform. One output diode is not func­tioning. Note the increased ripple con­tent. One diode was disconnected to
simulate an open or non-functioning out­put diode. Each vertical division repre­sents 20 volts and each horizontal divi­sion represents 5 milliseconds in time.
The machine was loaded with a resis­tance grid bank.

NOTE: Scope probes connected at

machine output terminals: (+)
probe to electrode, (-) probe to
work.

Volts/Div.................................20V/Div

Horizontal Sweep.................5 ms/Div

Coupling........................................DC

Trigger....................................Internal

SCOPE SETTINGS

MACHINE LOADED TO 180 AMPS AT 16 VDC

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TROUBLESHOOTING AND REPAIR

F-26F-26

POWER MIG 200

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ABNORMAL OPEN CIRCUIT VOLTAGE

OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”)

20.0 V 5 ms

0 Volts

This is NOT a typical DC output voltage
waveform. The output capacitors are
not functioning. Note the lack of “filter­ing” in the output waveform. The output
capacitor bank was disconnected. Each
vertical division represents 20 volts and
each horizontal division represents 5
milliseconds in time.

NOTE: Scope probes connected at

machine output terminals: (+)
probe to electrode, (-) probe to
work.

Volts/Div.................................20V/Div

Horizontal Sweep.................5 ms/Div

Coupling........................................DC

Trigger....................................Internal

SCOPE SETTINGS

TROUBLESHOOTING AND REPAIR

F-27F-27

POWER MIG 200

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This procedure takes approximately 20 minutes to perform.

CONTROL BOARD REPLACEMENT

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

DESCRIPTION

The following procedure will aid the technician in removing the control board for
replacement.

MATERIALS NEEDED

5/16” Nutdriver

TROUBLESHOOTING AND REPAIR

F-28F-28

POWER MIG 200

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CONTROL BOARD REPLACEMENT (continued)

PROCEDURE

1. Remove power to the machine.

2. Using a 5/16” nutdriver, remove the three
screws securing the tool tray.

3. Locate the control board.

4. Disconnect all associated plugs and leads
connected to the control board.

5. Depress the retaining pins on the sides of the
four nylon mounts to release the control
board. See Figure F.8.

6. Carefully remove the control board.

7. Mount the new board to the nylon mounting
pins.

8. Reconnect any plugs or leads previously
removed.

9. Replace the tool tray previously removed.

FIGURE F.8. - CONTROL BOARD MOUNTING PINS

DEPRESS
LOCKING TAB ON
MOUNTING PIN

F-29

TROUBLESHOOTING AND REPAIR

F-29

POWER MIG 200

This procedure takes approximately 50 minutes to perform.

WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

DESCRIPTION

The following procedure will aid the technician in removing the wire drive and tachometer
for repair or replacement.

MATERIALS NEEDED

5/16” Nutdriver

9/16” Nutdriver

Pliers

Small Flathead Screwdriver

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F-30

TROUBLESHOOTING AND REPAIR

F-30

POWER MIG 200

PROCEDURE

1. Remove power to the machine.

2. Lift cover to gain access to the wire drive.
See Figure F.9.

3. Using a pair of pliers, disconnect the gas
hose from the bottom of the wire drive.
See Figure F.10.

4. Using a 9/16” nut driver, remove the thick
black positive lead located just above the
gas hose. See Figure F.10.

NOTE: Disconnect lead from the wire drive

motor assembly, not the machine.

5. Using a 5/16” nutdriver, remove the three
mounting screws next to the wire drive
assembly. See Figure F.10.

6. Using a 5/16” nutdriver, remove the two
screws on the case front assembly. See

Figure F.11.

7. Carefully maneuver the wire drive assem­bly out the side of the machine to gain
access to plug J4. See Wiring Diagram.

8. Disconnect plug J4.

WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued)

FIGURE F.9. - WIRE DRIVE LOCATION

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Wire Drive

F-31

TROUBLESHOOTING AND REPAIR

F-31

POWER MIG 200

WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued)

FIGURE F.10. - WIRE DRIVE HOSE & LEAD LOCATION

FIGURE F.11. - MOUNTING SCREW LOCATIONS

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5/16" Sheet
Metal Screws

9/16" Bolt

5/16"
Monuting
Screws

Gas Hose

TROUBLESHOOTING AND REPAIR

F-32F-32

POWER MIG 200

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1. Place the new wire drive assembly into its
proper position.

2. Connect plug J4.

3. Maneuver assembly back into its original
position.

4. Replace all mounting screws previously
removed.

5. Using a 3/4” nut driver, replace the thick
black lead previously removed.

6. Reconnect the gas hose to the wire drive
assembly.

7. Close case wrap around cover.

WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued)

F-33

TROUBLESHOOTING AND REPAIR

F-33

POWER MIG 200

This procedure takes approximately 50 minutes to perform.

OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

DESCRIPTION

The following procedure will aid the technician in removing the output diode bridge
rectifier for repair or replacement.

MATERIALS NEEDED

3/8” Nutdriver

1/2” Nutdriver

5/16” Nutdriver

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F-34

TROUBLESHOOTING AND REPAIR

F-34

POWER MIG 200

OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)

PROCEDURE

1. Using a 3/8” nutdriver, remove the left side of the
case wraparound cover.

2. Locate the output diode bridge rectifier. See
Figure F.12.

3. Using a 1/2” nutdriver label and remove the four
thick black leads connected to the rectifier.

NOTE: Be sure to label lead terminals also.
Take note of washer placement upon removal.

4. Label and remove leads 104A and 104B. See
Wiring Diagram.

5. Using a 5/16” nutdriver locate and remove the
four bolts mounting the rectifier bracket to the
bottom of the machine. These bolts can be
accessed easily from the bottom of the machine.

See Figure F.13.

6. Carefully manipulate the output diode bridge
rectifier and the mounting bracket out of the left
side of the machine.

7. Using a 1/2” nutdriver remove the three bolts
mounting the bracket to the rectifier. The rectifi­er is now ready for repair or replacement. See

Figure F.13.

8. Mount the new rectifier to the mounting bracket
using the three 1/2” bolts.

9. Carefully manipulate the rectifier and mounting
bracket as a one back into the machine to its
proper location.

10. Mount the unit to the bottom of the machine

using the four 5/16” mounting bolts previously
removed.

11. Reconnect leads 104A and 104B previously

removed.

12. Reconnect the four thick black leads previously

labeled and removed using a 1/2” nutdriver.

13. Replace the left side of the case wraparound

cover.

OUTPUT DIODE
BRIDGE
RECTIFIER

FIGURE F.12. - OUTPUT DIODE BRIDGE RECTIFIER LOCATION

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F-35

TROUBLESHOOTING AND REPAIR

F-35

POWER MIG 200

OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)

FIGURE F.13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET

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5/16" Mounting
Bracket Mounting
Bolts

1/2" Rectifier
Mounting Bolts

Mounting
Bracket

F-36

NOTES

F-36

POWER MIG 200

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F-37

TROUBLESHOOTING AND REPAIR

F-37

POWER MIG 200

This procedure takes approximately 30 minutes to perform.

OUTPUT CAPACITORS REPLACEMENT

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

DESCRIPTION

The following procedure will aid the technician in removing the output capacitors for
repair or replacement.

MATERIALS NEEDED

3/8” Nutdriver

1/2” Wrench

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F-38

TROUBLESHOOTING AND REPAIR

F-38

POWER MIG 200

OUTPUT CAPACITORS REPLACEMENT (Continued)

PROCEDURE

1. Using a 3/8” nutdriver, remove the lower right
side case wraparound cover. See Figure F.14.

2. Locate capacitor bank. See Figure F.14.

3. Label and remove the five leads connected to
the capacitor bank using a 1/2” wrench. Note
washer position upon removal. See Figure

F.15.

4. Using a 3/8” nutdriver, remove the three capac­itor bank nuts and lock washers from the three
mounting bolts. See Figure F.15.

5. Remove the capacitor bank assembly from the
machine.

6. Place the new capacitor bank into its proper
location inside the machine.

7. Replace the three 3/8” nuts and lock washers
previously removed.

8. Using a 1/2” wrench, reconnect the five labeled
leads and associated washers previously
removed.

9. Replace the lower right side case wraparound
cover previously removed.

FIGURE F.14. - CAPACITOR BANK LOCATION

LOWER RIGHT
CASE WRAPAROUND
COVER

CAPACITOR BANK
ASSEMBLY

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F-39

TROUBLESHOOTING AND REPAIR

F-39

POWER MIG 200

OUTPUT CAPACITORS REPLACEMENT (Continued)

FIGURE F.15. - MOUNTING SCREW/BOLT LOCATIONS

}

{

3/8" Nuts &
Lock washers
(3 places)

Lead Mounting
Bolts

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F-40

NOTES

F-40

POWER MIG 200

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F-41

TROUBLESHOOTING AND REPAIR

F-41

POWER MIG 200

This procedure takes approximately 80 minutes to perform.

MAIN TRANSFORMER REPLACEMENT

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

DESCRIPTION

The following procedure will aid the technician in removing the main transformer for
repair or replacement.

MATERIALS NEEDED

3/8” Nutdriver

7/16” Nutdriver

1/2” Nutdriver

5/16” Nutdriver

Flathead Screwdriver

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F-42

TROUBLESHOOTING AND REPAIR

F-42

POWER MIG 200

MAIN TRANSFORMER REPLACEMENT (Continued)

PROCEDURE

1. Using a 3/8” nutdriver, remove both sides of
the case wraparound cover.

2. Using a 5/16” nutdriver, remove the tool tray.

3. Locate the main transformer. See Figure
F.16.

4. Label and disconnect leads X9, X10, 104B,
& 104C. See Figure F.17.

5. Using a flathead screwdriver, Label and dis­connect lead H1B and other associated lead
connected to the same terminal. These
leads are connected to the ON/OFF switch.

See Figure F.17.

6. Using a 7/16” nutdriver, Label and discon­nect leads X8, X7, X6, X5, X4, X3, & X2 from
the switch assembly. Note washer position
upon removal. See Figure F.18.

7. Using a 1/2” nutdriver, label and remove
lead X1 from the output diode bridge rectifi­er.

8. Using a 5/16” Nutdriver, open the rear
access panel. See Figure F.20.

9. Disconnect lead 118 from the rear access
panel. See Figure F.21.

10. Feed lead 118 toward the inside of the

machine.

11. Cut any necessary cable ties.

12. Remove any necessary wiring harnesses.

13. Disconnect lead 121. See Figure F.19.

14. Using a 1/2” nutdriver, remove the four main

transformer mounting bolts and associated
washers. See Figure F.16.

FIGURE F.16. - MAIN TRANSFORMER LOCATION

Main T ransformer

1/2" Mounting
Bolts

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F-43

TROUBLESHOOTING AND REPAIR

F-43

POWER MIG 200

MAIN TRANSFORMER REPLACEMENT (Continued)

15. Carefully maneuver the main transformer
out the left side of the machine.

NOTE: Two people may be needed to maneu-

ver the main transformer out of the
machine.

REPLACEMENT

1. Carefully maneuver the new main trans-

former back into the machine and onto its
mounting studs.

2. Using a 1/2” nutdriver, mount the main trans-

former in its proper position.

3. Reconnect leads 118 and 121 previously

removed.

4. Using a 5/16” nutdriver, close the rear

access panel previously opened.

5. Reconnect lead X1 to the output diode
bridge rectifier.

6. Reconnect leads X8, X7, X6, X5, X4, X3, &
X2 previously removed from the switch
assembly.

7. Reconnect lead H1B and the other associat­ed lead connected to the same terminal.
These leads are connected to the ON/OFF
switch.

8. Replace any necessary cable ties and wiring
harnesses.

9. Reconnect leads X9, X10, 104B, & 104C.
See Wiring Diagram.

10. Using a 5/16” nutdriver, replace the tool tray .

11. Using a 3/8” nutdriver, replace both sides of

the case wraparound cover.

X10

X9

104B

104C

H1B

FIGURE F.17. - LEADS X9, X10, 104B,104C, & H1B

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F-44

TROUBLESHOOTING AND REPAIR

F-44

POWER MIG 200

MAIN TRANSFORMER REPLACEMENT (Continued)

FIGURE F.18. - LEADS SWITCH LEADS

FIGURE F.19. - LEAD 121 & 118

X8

X7

X6

X5X4

X3

X2

Front

-

+

121

118

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F-45

TROUBLESHOOTING AND REPAIR

F-45

POWER MIG 200

MAIN TRANSFORMER REPLACEMENT (Continued)

FIGURE F.20. - REAR ACCESS PANEL

FIGURE F.21. - REAR ACCESS PANEL (CLOSE-UP)

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

5/16" Nut

REAR
ACCESS
PANEL

Lead 118

4

230V

208V

L1

L2

F-46

NOTES

F-46

POWER MIG 200

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F-47

TROUBLESHOOTING AND REPAIR

F-47

POWER MIG 200

This procedure takes approximately 45 minutes to perform.

FAN BLADE/MOTOR REPLACEMENT

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

DESCRIPTION

The following procedure will aid the technician in removing the fan blade and fan motor
for repair or replacement.

MATERIALS NEEDED

3/8” Nutdriver

5/16” Nutdriver

11/32” Open-End Wrench

Flathead Screwdriver

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F-48

TROUBLESHOOTING AND REPAIR

F-48

POWER MIG 200

FAN BLADE/MOTOR REPLACEMENT (Continued)

PROCEDURE

1. Using a 3/8” nutdriver, remove the lower
right side of the case wraparound cover.

2. Perform the Output Capacitor Bank

Removal Procedure.

3. Using a 5/16” nutdriver, remove the four fan
mounting screws from the rear of the
machine. See Figure F.22.

4. Using an open end 11/32” wrench, remove
the two fan motor mounting nuts and lock­washers. See Figure F.22.

5. Using a flathead screwdriver, loosen the fan
blade mounting band. See Figure F.22.

6. Pry the fan blade off of the mounting shaft.

NOTE: If fan blade cracks or breaks

upon removal, replace it.

7. Carefully manuver the fan motor and fan
blade out of the right side of the machine.

8. Replace the fan motor and fan blade if nec­essary.

9. Tighten the fan blade mounting band.

10. Carefully manuver the fan assembly into its

original position.

11. Replace the two 11/32” fan motor mounting

nuts and lockwashers.

12. Replace the four 5/16” fan assembly mount-

ing screws in the rear of the machine.

NOTE: Make sure the fan blade is free to rotate

when all of the mounting bolts are
replaced.

13. Perform the Output Capacitor Bank

Replacement Procedure.

14. Replace the lower right case cover.

REAR

5/16" Bolts

FIGURE F.22. - FAN MOUNTING BOLTS

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Fan
Motor

}

}

Fan
Blade

Fan
Mounting
Band

11/32"
Mounting
Nuts

F-49

TROUBLESHOOTING AND REPAIR

F-49

POWER MIG 200

This procedure takes approximately 40 minutes to perform.

OUTPUT CONTACTOR REPLACEMENT

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 or 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.

If for any reason you do not understand the test procedures or are unable to
perform the test/repairs safely, contact the Lincoln Electric service department
for technical troubleshooting assistance before you proceed. Call 1-800-833­9353(WELD).

WARNING

DESCRIPTION

The following procedure will aid the technician in removing the output contactor for repair
or replacement.

MATERIALS NEEDED

7/16” Wrench

5/16” Nutdriver

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F-50

TROUBLESHOOTING AND REPAIR

F-50

POWER MIG 200

OUTPUT CONTACTOR REPLACEMENT (Continued)

PROCEDURE

1. Using a 5/16” nutdriver, remove the three
screws securing the tool tray.

2. Locate the output contactor. See Figure
F.23.

3. Using a 7/16” wrench, label and remove the
two thick black leads at the top of the output
contactor. Note lead and washer placement
for reassembly.

4. Remove lead 107A and note lead place­ment. See Figure F.23.

5. Remove leads 106B and 106C. See Figure
F.23.

6. Using a 7/16” wrench, remove the three
mounting bolts from the output contactor.
Note washer positions for replacement. See

Figure F.24.

7. Replace output contactor.

8. Using a 7/16” wrench, mount the new output
contactor in its proper location.

9. Reconnect leads 106B, 106C, & 107A to
their proper terminals. See Wiring Diagram.

10. Reconnect the two thick black leads previ-

ously removed from the top of the output
contactor.

11. Replace the tool tray using a 5/16” nutdriv-

er.

107A

106C

106B

Output
Contactor

FIGURE F.23. - OUTPUT CONTACTOR LEADS

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F-51

TROUBLESHOOTING AND REPAIR

F-51

POWER MIG 200

OUTPUT CONTACTOR REPLACEMENT (Continued)

FIGURE F.24. - OUTPUT CONTACTOR MOUNTING BOLTS

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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7/16" Mounting
Bolts

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F-52

TROUBLESHOOTING AND REPAIR

F-52

POWER MIG 200

RETEST AFTER REPAIR

INPUT IDLE AMPS AND WATTS

OPEN CIRCUIT VOLTAGE

WIRE SPEED RANGE

Input Volts/Herts

230/60

Maximum Idle Amps

2.0

Maximum Idle Watts

150

35 - 40 VDC

50 - 700 IPM (1.27 - 17.8 m/minute)

POWER MIG 200

G-1

ELECTRICAL DIAGRAMS

G-1

TABLE OF CONTENTS

-ELECTRICAL DIAGRAMS SECTION-

ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2

CONTROL PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3

CONTROL PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

ELECTRICAL DIAGRAMS

G-2

WIRING DIAGRAM -

G-2

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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POWER MIG 200 (208/230V)

TO SINGLE PHASE

SUPPLY LINE

TO GROUND PER

NATIONAL ELECTRICAL

CODE

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

H3 H4

230V

G

8

16

H2

208V

RECONNECT

PANEL

L1 L2

1

J2

4

BAFFLE
MOUNTED
RECTIFIER
DIODE
BRIDGE

3

6

106A

L1

H1

1

J1

9

W

B

X9

+

106B

L2

H4

LINE

SWITCH

S1

FAN

MOTOR

114A

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE

B - BLACK
W - WHITE

1

J3

2

INDICATES CONNECTOR CAVITY No.

R - RED
U - BLUE

** CAVITY

NUMBERING SEQUENCE

(NON-LEAD SIDE OF CONNECTOR)

3

1

PA

4

6

X10

-

X10

27.8V

X9

X9

X8

POWER

X7

X6

X5

X4

X3

X2

X1

H1

H5

H2

H1

H3

TRANSFORMER

H5H1B

G

F

E

D

C

B

A

J4 (TRIGGER,

TACHOMETER,

MOTOR SIDE)

1

5

106B

CONTACTOR

TAP SELECTOR
SWITCH

NOTES:

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF

IMMEDIATE AND FUTURE APPLICATIONS.

N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIVE”. TO CHANGE POLARITY, TURN

THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK
STUD.

4

8

108A

116A

GAS

106C

SOLENOID

107A

SINGLE PHASE

BRIDGE

RECTI FIER

116B

GUN
TRIGGER

1

2

B

R

T
A

U

C
H

B

CONTROL BOARD

101A

102A

103A

104A

105A

106A

107A

108A

109A

110A

111A

112A

113A

114A

115A

116A

FOR SPOOL GUN OPTION

104B

103A

R2

WIRE FEED
SPEED

JUMPER PLUG
INSTALLED FOR
NON-SPOOL GUN
OPERATION

RECTIFIER
ASSEMBLY

THERMOSTAT

PA

**

1

2

3

4

5

6

TO
WORK

104A

TRANSFORMER

THERMOSTAT

104C

109A

113A

J5

1

1

116B

2

2

104C

105A

3

3

106C

4

4

5

104D

6

105B

J4

**

1

324

+

-

MOTOR/

GEARBOX

325

R

U

B

B

W

3

4

P.M.

W

104D

111A

2

3

115A

4

101A

5

102A

6

105B

7

8

112A

1

2

3

4

5

6

7

8

J1

9

10

11

12

13

14

15

16

1
2
3

J2

4

5

6

1

J3

2

C1 AND C2
31,000 MFD
50V

C1

C2

+

+

40 OHMS

R1

50 W

OUTPUT

CHOKE

10-10-2000

L11424

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ELECTRICAL DIAGRAMS

G-3

SCHEMATIC - CONTROL PC BOARD

G-3

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-

vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.

ELECTRICAL DIAGRAMS

G-4

PC BOARD ASSEMBLY-CONTROL

G-4

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

3. 30

3. 10

B

TP1

TP1

.20

R

R111R112

0

Q18

R119

C44

1

C45

R125

DZ6

C33

R113

C42

X9

G3851-1

G3851-1

X7

R108

R121

R118

R115

C43

Q16

R116

R114

R117

R98

R94 C37

R99

R100

C39

D19

D18

R122

Q12

C47

C29

R65 R7 1
C28

R77

R109

C34

C31

C53

R110

Q19

Q14 R92

R95

R97

C50

C38

D9

C40

C46

R101

R106

R123

R47
R61

R124

0

R72

TP1

R96

ITEM REQ’D PART No. DESCRIP TION

FOR ITEMS BELOW, REFER TO ELEC TRON IC COM PONEN T DAT ABA SE FOR C OMPON ENT SPECIF ICA TION S

R16,R17 ,R27,R70,R118 5 S25000-1212SMT RESISTOR,SMD,METAL FILM,1/10W,12.1K,1

R18,R75 2 S25000-1000SMT RESISTOR,SMD,METAL FILM,1/10W,100OHMS

R19,R34 ,R61,R110, R111, R11 9,R 123 7 S2 500 0-1 502S MT RE SIS TOR, SMD, MET AL FI LM, 1/10W,1 5.0 K,1

R20,R32 ,R73,R127 4 S25000-1002SMT RESISTOR,SMD,METAL FILM,1/10W,10.0K,1

R22 1 S25000-6191SMT RESISTOR,SMD,METAL FILM,1/10W,6.19K,1

R23 1 S25000-2211SMT RESISTOR,SMD,METAL FILM,1/10W,2.21K,1

R28,R29 ,R50,R51 4 S25000- 8252SMT RESISTOR,SMD,METAL F IL M, 1/10W,82.5K,1

R30,R47 ,R88,R96,R97,R116,R124 7 S25000-2002SMT RESISTOR,SMD,METAL FILM,1/10W,20.0K,1

R31,R35 2 S25000-2670SMT RESISTOR,SMD,METAL FILM,1/10W,267OHMS

R37,R45 2 S18380-14 THERMISTOR,PTC,500OHMS,28mA

R38 1 S25000-6813SMT RESISTOR,SMD,METAL FILM,1/10W,681K,1%

R39,R63 ,R79,R90 4 S25000-2 210SMT RESISTOR,SMD,METAL FILM,1/10W,221OHMS

R41,R64 2 S25001-3321SMT RESISTOR,SMD,3.32K,1/4W,1206,1%,TR

R42,R12 2 2 S25000-1003SMT RESISTOR,SMD,METAL FILM,1/10W,100K,1%

R44 1 S25000-3570SMT RESISTOR,SMD,METAL FILM,1/10W,357OHMS

R46,R80 ,R115 3 S25000- 5111SMT RESISTOR,SMD,METAL FILM,1/10W,5 .11K,1

PO WER MIG 200

PO WER MIG 200
CONTROL

R41

R50
C23

R51

C35

Q10

R59

R104

CONTROL

C24

R42

X6

C22

R57

R58

C26

R107

J3

R44

R80

R81

C30

R66

DZ4

R53

C25

D14

Q7

R32

R25

R13

C11

X3

R11

R5

D5

X1

9

R24

R14

TP1

TP

C12

3

R68

R52

R34

Q4

Q5

R29

R17

R26

R16

D10

R28

R43

R36

C16

R15

C15

R27

R30

Q6

R35

R20

R33

R31

R39

C14

C13

X4

R8

C6

R18

Q2

Q3

R6

R55

R56

C18

X5

C8

R82

C32

R21

R84

R127

R23

R7

R40

C19

D11

C9

R9

C7

R38

R126

D13

D8

C17

R19

TP

TP

2

C4 R12

D6

C5

C48

TP

D7

TP

DZ1

R4

4

R3

7

Q9

TP

C1

X2

Q1

R85

R22

C10

R37R48

J2

R10

D12

R83

1

3

D3

DZ9 DZ8

R2

D1

R1 C2

D4

6

TP

C3

D2

C49

J1

R89

C20 C21

R88

R73

R86

R87

TP1

X8

R78

2

R74

C36

R76

C52

Q13

4

R75

C54

R79

D17

C41

TP

R64

R70

R54

R102

Q17

8

TP
Q15

R90

R93

R91

C27

5

D15

R62

R60

R63

DZ5

Q11

R103

R46

R45

Q8

R105

D16

R49

R48,R49 2 S25004-2430SMT RESISTOR,SMD,1W,243OHMS,1%

R52 1 S25000-4751SMT RESISTOR,SMD,METAL FILM,1/10W,4.75K,1

R53,R10 8 2 S25 000-3 922SMT RESISTOR,SMD,METAL FILM,1/10W,39.2K,1

R54 1 S25056-2SMT TRIMMER,SMD,MT,1/4W,2K,10%,LINEAR

R56 1 S25001-1212SMT RESISTOR,SMD,12.1K,1/4W,1206,1%

R58,R81 2 S25001-2672SMT RESISTOR,SMD,26.7K,1/4W,1206,1%,TR

R59 1 S25000-9091SMT RESISTOR,SMD,METAL FILM,1/10W,9.09K,1

R60 1 S25000-2431SMT RESISTOR,SMD,METAL FILM,1/10W,2.43K,1

R62 1 S25000-3320SMT RESISTOR,SMD,METAL FILM,1/10W,332OHMS

R66 1 S25000- 2432SMT RESISTOR,SMD,METAL FILM,1/10W,24.3K,1

R68 1 S25000-3741SMT RESISTOR,SMD,METAL FILM,1/10W,3.74K,1

R71,R87 ,R106 3 S25000- 1001SMT RESISTOR,SMD,METAL FILM,1/10W,1 .00K,1

R74 1 S25000- 1782SMT RESISTO R,SMD,M ETAL F I LM,1/10W,17.8K,1

R76,R10 0 2 S25000-8251SMT RESISTOR,SMD,METAL FILM,1/10W,8.25K,1

R77,R78 ,R89 3 S25000- 6190SMT RESISTOR,SMD,METAL FILM,1/10W,619OHMS

R82,R85 2 S25001-5621SMT RESISTOR,SMD,5.62K,1/4W,1206,1%,TR

R83 1 S25005-1SMT RESISTOR,SMD,METAL STRIP,3W,0.05OHMS,

R84 1 S25001-2212SMT RESISTOR,SMD,22.1K,1/4W,1206,1%

R86 1 S25000-5622SMT RESISTOR,SMD,METAL FILM,1/10W,56.2K,1

R91,R10 2 2 S25000-2000SMT RESISTOR,SMD,METAL FILM,1/10W,200OHMS

R92,R11 4,R117 3 S25000-1821SMT RESISTOR,SMD,METAL FILM,1/10W,1 .82K,1

T1

R93,R99 2 S25000- 6811S MT RES ISTO R,S MD,M ETAL F ILM ,1/10W,6.81K,1

R95 1 S25000- 4750SMT RESISTO R,SMD,M ETAL F ILM ,1/10W,475OHMS

R101 1 S25 001-1 502SMT RESISTOR,SMD,15K,1/4W,1206,1% , TR

R103 1 S25001-1001SMT RESISTOR,SMD,1K,1/4W,1206,1%,TR

R104,R1 07 2 S25001-6191SMT RESISTOR,SMD,6.19K,1/4W,1206,1%,TR

R109 1 S25056-3SMT TRIMMER,SMD,MT,1/4W,50K,10%,LINEAR

R128

R112 1 S25 000-6 810SMT RESISTOR,SMD,METAL FILM,1/10W,681OHMS

R113 1 S25 000-2 212SM T RES ISTO R,SMD,M ETAL F ILM,1/10W,22.1K,1

R125 1 S25 000-7 500SMT RESISTOR,SMD,METAL FILM,1/10W,750OHMS

R128,R1 29 2 S2 5001-2490SMT RESISTOR,SMD,249OHMS,1/4W,1206,1%,TR

R129

T1 1 S20375-8 TRANSFORMER,PCB,PWM,FLYBACK

X1 1 S25 068- 11S MT IC,SMD,VOLTAGE REGULATOR,STEP-DOWN,AD

X2 1 S23060-1SMT IC,SMD,SWITCH,LO-SIDE,2.2A,60V,SOT-22

X3, X9 2 S151 28-11SMT IC,SMT,COMPARATOR,QUAD,2901D

DZ7

X4 1 S25067-1SMT IC,BIPOLAR,TIMER,SOIC-14

X5 1 S25 068- 2SM T IC ,SMT, CMOS,DR IVER,MOSFET,2113(SS)

X6 1 S15 128- 18S MT IC,O P-AM P,SM T,QUA D,HIGH-PERF,33074D

X7 1 M13552-2SMT IC,CONVERTER,F/V ,2907, SO-8

X8 1 S15 128-4 SMT OP- AMP, SMD,Q UAD, GEN- PURP OSE,22 4D

ITEM REQ’D PART No. D ESCRIPT ION

11G3851-BP.C. BO ARD BL ANK

2.01 oz.E3539 E LECT RI CAL IN SU LATI ON COMP OUN D

FOR ITEMS BELOW, REFER TO ELECTR ONIC COMPONENT DATABASE FOR COMPONENT SPECIFICAT ION S

C1 1 S13490-179 CAPACITOR,ALEL,1000,35V,20%

C2 1 S25020-5SMT CAPACITOR,SMD,CERAMIC,2700pF,50V,5% ,X

C3 1 S13490-182 CAP,ALEL,3300,63V,20%

C4 1 S25020-10SMT CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,

C5 1 S25024 -5SMT C APACITOR,SM D,TANTALUM ,4.7MF,3 5V,10%,

C6,C39,C 48 3 S2502 0-4SMT CAPACITOR,SMD,CERAMIC,820 pF,50V,5% ,CO

C7,C9,C 11,C14,C15,C17,C18 26 S25020-3SMT CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X

C19,C22 ,C24,C27,C28,C29

C32,C34 ,C35,C37,C38,C40

C41,C44 ,C47,C 50,C52,C53,C54

C8 1 S25024 -2SMT C APACITOR,SM D,TANTALUM ,1.0MF,3 5V,10%,

C10 1 S 25020-12SMT C APACITOR,SMD,CERAMIC,100pF,100V,5%,C

N.C.

C12,C23 ,C30,C31,C36,C42,C43 6 S25020-2SMT CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%

C13,C16 2 S 25020-14SMT CAPACITOR,SMD,CERAMIC,330pF,100V,5%,C

C20,C21 2 S 25024-10SMT CAPACITOR,SMD,TANTALUM,22MF,25V,10%,S

C25,C26 2 S 25020-7SMT CAPACITOR,SMD,CERAMIC,0.22MF,50V,20%,

C33 1 S 25020-6SMT CAPACITOR,SMD,CERAMIC,4700pF,50V,5%,C

C45 1 S 25024-6SMT CAPACITOR,SMD,TANTALUM,22MF,16V,10%,S

C46 1 S 25024-8SMT CAPACITOR,SMD,TANTALUM,10MF,16V,10%,S

C49 1 S 25024-3SMT CAPAC IT OR, SMD ,TA NT ALUM,2.2MF,20V,10%,

D1,D2,D 3,D4,D5,D16 6 S25040-11SMT DIODE,SMD,1A,600V,S403A,ULTRA-FAST RE

D6,D9,D 10,D14,D17 5 S25049-4SMT DIODE,SMD,DUAL,200MA,30V,SCHOTTKY,SOT

D7 1 S25049-2SMT DIODE,SMD,1A,30V,SMA,SCHOTTKY

D8,D11,D 13 3 S2504 0-1SMT DIODE,SMD,1A,400V,FAST RECOVERY,DO-21

D12 1 S 25040-9SMT DIODE,SMD,3A,200V,D0-214AB,U LTRA-FAST

D15,D18 ,D19 3 S 25040-4SMT DIODE,SMD,DUAL,0.200A,70V,UFR

DZ1 1 S25 044-2SM T ZENER DIODE,SMD,3W,8.2V,5%, SMB

DZ4 1 S25 045-1SM T ZENER_DIODE,SMD,225mW,12V,5%,SOT-23

DZ5 1 S25 044-1SM T ZENER DIODE,SMD,3W,5.1V,5%, SMB

DZ6,D Z7 2 S25046-1SMT ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123

DZ8,D Z9 2 T 12702-26 ZENER DIODE, 1W,27V,10% 1N4750A

J1 1 S 24 02 0 -1 6 CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN

J2 1 S 24 020-6 CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN

J3 1 S 24 020-2 CONNECTOR,MOLEX,MINI,PCB,2-PIN,TIN

Q1, Q9 2 T 127 04-88SMT TRANSISTOR,SMD,NMF,T263,45A,100V(SS)

Q2 1 S 25 051-4SMT TRANSISTOR,SMD,NMF,SOT-23,0.115A,60V,

Q3, Q4,Q 5,Q 6,Q 7, Q11,Q13,Q14 12 S25050-1SM T TRANSISTOR,SMD,NPN,0.5A,40V,SOT-23,MM

Q15, Q16 ,Q1 7, Q19

Q8, Q10,Q12,Q18 4 S25050-2SMT TRANSISTOR,SMS,PNP,SOT23,0.5A, 40V,MM

R1,R55 2 S 25000-2801SMT RESISTOR,SMD,METAL FILM,1/10W,2.80K,1

R2 1 S25000-3162SMT RESISTOR,SMD,METAL FILM,1/10W,31.6K,1

R3,R7,R 126 3 S2500 1-2671SMT RESISTOR,SMD,2.67K,1/4W,1206,1%,TR

R4 1 S25001-24R9SMT RESISTOR,SMD,24.9OHMS,1/4W,1206,1% ,TR

R5,R33,R 36,R120 4 S25000-5621SMT RESISTOR,SMD,METAL FILM,1/10W,5.62K,1

R6,R26,R 121 3 S 25000-3322SMT RESISTOR,SMD,METAL FILM,1/10W,33.2K,1

R8 1 S25001-2001SMT RESISTOR,SMD,2K,1/4W,1206,1%,TR

R9,R21,R 40,R105 4 S25001-1000SMT RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR

R10 1 S 25001-15R0SMT RESISTOR,SMD,15.0OH MS,1/4W,1206,1%,TR

R11,R72 ,R94 3 S 25000-1652SMT R ESISTOR,SMD,METAL FILM,1/10W,16.5K,1

R12 1 S 25000-6812SMT R ESISTOR,SMD,METAL FILM,1/10W,68.1K,1

R13,R25 ,R43,R98 4 S25000-3321SMT RESISTOR,SMD,METAL FILM,1/10W,3.32K,1

R14,R24 ,R57 3 S 25001-1004SMT R ESISTOR,SMD,1.00M,1/4W,1206,1%,TR

R15,R65 2 S 25000-4753SMT RESISTOR,SMD,METAL FILM,1/10W,475K,1%

UNLESS OTHERWISE SPECIFIED:

CAPACITANCE= MFD/VOLTS
INDUCTA NCE = H ENRIE S
RESISTANCE = OHMS

0 5.805. 60.20

THIS SHEET CONTAI NS PROPRIETARY I NFORMATION OWNED B Y THE LINCO LN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DIS CLOSED OR USED WI TH O U T THE EX P RES S WRI T TE N P ERMI S SI O N OF THE LIN CO L N ELE C TRI C C OM PAN Y, CLE VE LAN D, OHI O U.S. A.

UNLESS OTHERWISE SPECIFIED TOLERANCE
MAN UF AC TU RI NG T OL E RANCE PER E2056
ON 2 PLACE DECIMALS IS ± .0 2

ON 3 PL ACE DECIMALS IS ± .002

ON ALL ANGLES IS± .5 OF A DEGR EE
MATERIAL TOLERANCE (" ") TO AGREE

WITH PUBLISHED STANDARDS.

EN-170

DO NOT SCALE THIS DRAWING

t

Chg. Sheet No."X" INFO.

XA 10-20-20 00

DESIG N IN FORM A TIO N
DRA W N BY:
ENGINEER:

APPRO VED:

REFERENCE:

L11110-1

SUPERSEDING:

EQU I PM ENT T YPE :
SUBJECT:
SCALE:

DATE:

DRAWING No.:

3851-1

SVM ERROR REPORTING FORM

We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.

If you discover new or different “Problems or Symptoms” that are not covered in the three col­umn troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.

Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199

FAX [phone]

SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________

Please give detailed description below:
___________________________________________________________________________

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SD287 01/99

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