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IM693
POWER MIGâ„? 200 June, 2002
For use with machine Code Numbers 10564
For use with machine Code Numbers
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
Copyright © 2001 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
POWER MIG 200
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
4.c. Protect other nearby personnel with suitable, non-flammable
area of physical contact with work and ground.
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
� AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically “hot�.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
POWER MIG 200
iii iii
SAFETY
CYLINDER may explode
WELDING SPARKS can
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or cylinders, associated equipment, and CGA publication P-l,
welding. They may explode. “Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil 1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding 8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building switch at the fuse box before working on
framework or other locations away from the welding area the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir- 8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains Electrical Code, all local codes and the manufacturer’s
or cables until they fail. recommendations.
6.h. Also see item 1.c. 8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
POWER MIG 200
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
Mar. �93
soudage. Utiliser des lunettes avec écrans lateraux dans les
POWER MIG 200
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
vi
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions.................................................................................................A-2
Uncrating the POWER MIG 200 ............................................................................A-2
Location .................................................................................................................A-2
Input Power, Grounding and connection Diagrams .................................A-2 thru A-3
Output Polarity Connections ..................................................................................A-3
Gun and Cable Installation ....................................................................................A-4
Shielding Gas ........................................................................................................A-4
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
Product Description ...............................................................................................B-2
Recommended Processes and Equipment ...........................................................B-2
Welding Capability .................................................................................................B-2
Limitations..............................................................................................................B-2
Description of Controls ..........................................................................................B-2
Wire Drive Roll.......................................................................................................B-2
Wire Size Conversion parts ...................................................................................B-2
Procedure for Changing Drive Roll ........................................................................B-3
Wire Reel Loading .................................................................................................B-3
Mounting of 10 to 30 lbs. Spools ...........................................................................B-3
To Start the Welder................................................................................................B-3
Feeding Electrode..................................................................................................B-4
Idle Roll Pressure Setting ......................................................................................B-4
Making a Weld .......................................................................................................B-4
Avoiding Wire Feeding Problems ..........................................................................B-5
Fan Control ............................................................................................................B-5
Input Line Voltage Protection.................................................................................B-5
Wire Feed overload Protection ..............................................................................B-5
Welding Thermal Overload Protection...................................................................B-5
Accessories .....................................................................................................Section C
Drive Roll Kits ........................................................................................................C-1
Aluminum Feeding Kit (Optional K1703-1) ............................................................C-1
K363P Readi-Reel Adapter ...................................................................................C-1
Dual Cylinder Mounting Kit (K1702-1) ...................................................................C-1
Alternative Magnum GMAW Gun and Cable Assemblies .....................................C-1
Magnum Gun Connection Kit (Optional K466-6) ...................................................C-1
Spool Gun and Adapter Kit (Optional K1809-1) ....................................................C-1
Making a Weld with the Spool Gun Adapter Kit and Spool Gun Installed .............C-2
POWER MIG 200
vii vii
MASTER TABLE OF CONTENTS FOR ALL SECTIONS (cont.)
Page
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Maintenance ............................................................................................D-1
Drive Rolls and guide Tubes .................................................................................D-1
Contact Tip and Gas Nozzle Installation ...............................................................D-1
Gun Tubes and Nozzles ........................................................................................D-1
Cable Cleaning ......................................................................................................D-1
Liner Removal and Replacement ..........................................................................D-2
Gun Handle Disassembly ......................................................................................D-3
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ............................................................................E-2 thru E-4
Wiring Diagram and Dimension Print ............................................................Section F
Parts Manual ....................................................................................................Appendix
POWER MIG 200 ..................................................................................P372 Series
Magnum 250L Gun .....................................................................................P202-H.2
POWER MIG 200
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS � POWER MIG 200
INPUT � SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current @ 150 Amp Rated Output Input Current @ 150 Amp Rated Output
208/230/50/60 Hz 28/26 Amps 36/33
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
30% 200 Amps 22 Volts
40% 180 Amps 23 Volts
60% 150 Amps 24 Volts
OUTPUT
Welding Current Range Maximum Open Circuit Voltage Welding Voltage Range
30 � 200 Amps 40 Volts 13.5-22 Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES
75°C Copper Wire 75°C Copper Wire
Input Ampere in Conduit in Conduit
Input Voltage/ Fuse or Breaker Rating On AWG (IEC) Sizes AWG (IEC) Sizes
(For lengths (For lengths
Frequency (Hz) Size (Super Lag) Nameplate up to 100 ft.) exceeding 100 ft.)
10 (6 mm2) 8 (10 mm2)
208/50/60 60 36
10 (6 mm2) 8 (10 mm2)
230/50/60 60 33
NOTE: Use #10 AWG Grounding Wire
PHYSICAL DIMENSIONS
Height Width Depth Weight
31.79 in 18.88 in 38.78 in 210 Ibs
808 mm 480 mm 985 mm 95 kg
WIRE SPEED RANGE
Wire Speed 50 � 700 IPM (1.27 � 17.8 m/minute)
POWER MIG 200
A-2
A-2 INSTALLATION
INPUT POWER, GROUNDING AND
Read entire installation section before starting
installation. CONNECTION DIAGRAMS
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
WARNING
� Do not touch electrically live parts such as
ELECTRIC SHOCK can kill. output terminals or internal wiring.
� Only qualified personnel should perform � All input power must be electrically dis-
this installation. connected before proceeding.
� Only personnel that have read and under-
stood the POWER MIG 200 Operating
1. Before starting the installation, check with the local
Manual should install and operate this
power company if there is any question about
equipment.
whether your power supply is adequate for the volt-
� Machine must be grounded per any nation-
age, amperes, phase, and frequency specified on
al, local or other applicable electrical
codes. the welder nameplate. Also be sure the planned
installation will meet the U.S. National Electrical
� The POWER MIG power switch is to be in
the OFF position when installing work Code and local code requirements. This welder
cable and gun and when connecting other
may be operated from a single phase line or from
equipment.
one phase of a two or three phase line.
UNCRATING THE POWER MIG 200 2. Models that have multiple input voltages specified
on the nameplate (e.g. 208/230) are shipped con-
Cut banding and lift off cardboard carton. Cut banding nected for the highest voltage. If the welder is to be
holding the machine to the skid. Remove foam and operated on lower voltage, it must be reconnected
corrugated packing material. Untape accessories from according to the instructions in Figure A.1 for dual
Gas Bottle Platform. Unscrew the two wood screws voltage machines and Figure A.2 for triple voltage
(at the Gas Bottle Platform) holding the machine to machines.
the skid. Roll the machine off the skid assembly.
WARNING
LOCATION
Make certain that the input power is electrically
Locate the welder in a dry location where there is free disconnected before removing the screw on the
circulation of clean air into the louvers in the back and reconnect panel access cover.
out the front. A location that minimizes the amount of
smoke and dirt drawn into the rear louvers reduces
the chance of dirt accumulation that can block air pas-
sages and cause overheating.
POWER MIG 200
A-3 A-3
INSTALLATION
FIGURE A.1 � Dual Voltage Machine Input Connections
50/60 HZ
3. The 208/230 volt 50/60 Hz model POWER MIG is FIGURE A.3 � Receptacle Diagram
shipped with a 7 ft. input cable and plug connected
to the welder. CONNECT TO A SYSTEM
GROUNDING WIRE. SEE
THE UNITED STATES
4. Using the instructions in Figure A.3, have a quali- NATIONAL ELECTRICAL
fied electrician connect a receptacle (Customer CODE AND/OR LOCAL
CODES FOR OTHER
Supplied) or cable to the input power lines and the
DETAILS AND MEANS FOR
system ground per the U.S. National Electrical PROPER GROUNDING.
Code and any applicable local codes. See
CONNECT TO HOT WIRES
“Technical Specifications� at the beginning of this
OF A THREE-WIRE, SINGLE
chapter for proper wire sizes. For long runs over PHASE SYSTEM OR TO ONE
100 feet, larger copper wires should be used. Fuse PHASE OF A TWO OR
THREE PHASE SYSTEM.
the two hot lines with super lag type fuses as
shown in the following diagram. The center contact
in the receptacle is for the grounding connection. A
green wire in the input cable connects this contact
OUTPUT POLARITY CONNECTIONS
to the frame of the welder. This ensures proper
grounding of the welder frame when the welder
The welder, as shipped from the factory, is connected
plug is inserted into a grounded receptacle.
for electrode positive (+) polarity. This is the normal
polarity for GMA welding.
FIGURE A.3 � Receptacle Diagram
If negative (�) polarity is required, interchange the
CONNECT TO A SYSTEM
GROUNDING WIRE. SEE THE connection of the two cables located in the wire drive
UNITED STATES NATIONAL
compartment near the front panel. The electrode
ELECTRICAL CODE AND/OR
cable, which is attached to the wire drive, is to be con-
LOCAL CODES FOR OTHER
DETAILS AND MEANS FOR nected to the negative (�) labeled terminal and the
PROPER GROUNDING.
work lead, which is attached to the work clamp, is to
be connected to the positive (+) labeled terminal.
CONNECT TO HOT WIRES
OF A THREE-WIRE, SINGLE
PHASE SYSTEM OR TO ONE
PHASE OF A TWO OR
THREE PHASE SYSTEM.
POWER MIG 200
A-4 A-4
INSTALLATION
2. Remove the cylinder cap. Inspect the cylinder
GUN AND CABLE INSTALLATION valves and regulator for damaged threads, dirt,
dust, oil or grease. Remove dust and dirt with a
clean cloth.
The Magnum 250L gun and cable provided with the
POWER MIG 200 is factory installed with a liner for
DO NOT ATTACH THE REGULATOR IF OIL,
.035-.045" (0.9-1.2 mm) electrode and an .035" (0.9
GREASE OR DAMAGE IS PRESENT! Inform your
mm) contact tip. Be sure that the contact tip, liner, and
gas supplier of this condition. Oil or grease in the
drive rolls all match the size of the wire being used.
presence of high pressure oxygen is explosive.
WARNING
3. Stand to one side away from the outlet and open
the cylinder valve for an instant. This blows away
Turn the welder power switch off before installing
any dust or dirt which may have accumulated in
gun and cable.
the valve outlet.
1. Lay the cable out straight.
WARNING
2. Unscrew knurled screw on the drive unit front end
Be sure to keep your face away from the valve
(inside wire feed compartment) until tip of screw no
outlet when “cracking� the valve.
longer protrudes into gun opening as seen from
front of machine.
4. Attach the flow regulator to the cylinder valve and
3. Insert the male end of gun cable into the female
tighten the union nut(s) securely with a wrench.
casting through opening in front panel. Make sure
connector is fully inserted and tighten knurled
NOTE: If connecting to 100% CO 2 cylinder, an
screw.
additional regulator adapter must be installed
between the regulator and cylinder valve. If
4. Connect the gun trigger connector from the gun
adapter is equipped with a plastic washer, be sure
and cable to the mating receptacle inside the com-
it is seated for connection to the CO2 cylinder.
partment located above the gun connection made
5. Attach one end of the inlet gas hose to the outlet
in item 3 above. Make sure that the keyways are
fitting of the flow regulator, the other end to the
aligned, insert and tighten retaining ring.
POWER MIG 200 rear fitting, and tighten the union
SHIELDING GAS nuts securely with a wrench.
(For Gas Metal Arc Welding Processes)
6. Before opening the cylinder valve, turn the regula-
tor adjusting knob counterclockwise until the
Customer must provide cylinder of appropriate type
adjusting spring pressure is released.
shielding gas for the process being used.
7. Standing to one side, open the cylinder valve slow-
A gas flow regulator, for Argon blend gas, and an inlet
ly a fraction of a turn. When the cylinder pressure
gas hose are factory provided with the POWER MIG
gauge pointer stops moving, open the valve fully.
200. When using 100% CO2 an additional adapter will
be required to connect the regulator to the gas bottle.
WARNING
WARNING
Never stand directly in front of or behind the flow
CYLINDER may explode if regulator when opening the cylinder valve. Always
damaged. stand to one side.
___________________________________________
� Gas under pressure is explosive. Always
keep gas cylinders in an upright position
and always keep chained to undercarriage
8. The flow regulator is adjustable. Adjust it to the
or stationary support. See American
flow rate recommended for the procedure and
National Standard Z-49.1, “Safety in
process being used before making the weld.
Welding and Cutting� published by the
American Welding Society.
Install shielding gas supply as follows:
1. Set gas cylinder on rear platform of POWER MIG
200. Hook chain in place to secure cylinder to rear
of welder.
POWER MIG 200
B-1
OPERATION
B-1
Read entire Operation section before
operating the POWER MIG 200.
WARNING
ELECTRIC SHOCK can kill.
� Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
� 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 contain-
ers.
ARC RAYS can burn eyes
and skin.
� Wear eye, ear and body protec-
tion.
Observe all safety information throughout
this manual.
POWER MIG 200
B-2
B-2 OPERATION
PRODUCT DESCRIPTION LIMITATIONS
The output voltage/current of the POWER MIG 200 is
The POWER MIGâ„? 200 is a complete semiautomatic subject to vary if the input power to the machine
DC voltage arc welding machine built to meet NEMA varies, due to its tapped transformer power topology.
specifications. It combines a tapped transformer volt- In some cases an adjustment of WFS preset and/or
age power source with a constant speed wire feeder voltage tap selection may be required to accommo-
to form a reliable robust performance welding system. date a significant drift in input power.
A simple control scheme, consisting of continuous full
DESCRIPTION OF CONTROLS
range wire feed speed control, and 7 output voltage
tap selections provides versatility with ease of use and
Power ON/OFF Switch � Place the lever in the "ON"
accuracy.
position to energize the POWER MIG 200.
Voltage Control � Seven voltage tap selections are
Other features include a 2" (51 mm) O.D. wire reel
provided Labeled "A" (minimum voltage) through "G"
spindle with adjustable brake, an integral gas cylinder
(maximum voltage). It should only be adjusted when
mounting undercarriage, an adjustable Argon blend
not welding. The control selection can be preset to the
flow regulator with cylinder pressure gauge and inlet
setting specified on the Procedure Decal on the inside
hose, a 12 ft. (3.6 m) Magnum 250L GMAW gun and
of the wire compartment door.
cable with fixed (flush) nozzle, a 7 ft. (2.1 m) power
Wire Speed Control � This controls the wire feed
cable with plug, and a 10 ft. (3.0 m) work cable with
speed from 50 � 700 inches per minute (1.2 � 17.8
clamp.
m/min). Wire speed is not affected when changes are
made in the voltage control.
Optional Spool Gun and Adapter kit, Dual Cylinder
Mounting kit and Aluminum Feeding Kit for push feed-
ing with standard built in feeder are also available.
WIRE DRIVE ROLL
RECOMMENDED PROCESSES AND The drive rolls installed with the POWER MIG each
EQUIPMENT have two grooves, both for .030-.035" (0.8-0.9 mm)
solid steel electrode. Drive roll size is indicated by the
The POWER MIG 200 is recommended for GMA stenciling on the exposed side of the drive roll. If feed-
welding processes using 10 to 44 lb (4.5 to 20 kg) 2" ing problems occur, then the drive roll may be
(51 mm) I.D. spools or Readi-Reel® coils (with option- reversed or changed. See "Procedure for Changing
al adapter) of .025" through .045" (0.6 � 1.2 mm) solid Drive Roll" in this section.
steel, .035" (0.9 mm) stainless, 3/64" (1.2 mm) alu-
minum and .045" (1.2 mm) Outershield®; as well as
.035" (0.9 mm) and .045" (1.2 mm) Innershield® self- WIRE SIZE CONVERSION PARTS
shielding electrodes.
The POWER MIG 200 is rated to feed .025 through
The POWER MIG is factory equipped to feed .035" .045" (0.6-1.2 mm) solid or cored electrode sizes.
(0.9 mm) electrodes. It also includes a 200A, 60% The drive roll kits and Magnum 250L gun and cable
duty cycle (or 250A, 40% duty cycle) rated, 12 ft. (3.6 parts are available to feed different sizes and types of
m) GMAW gun and cable assembly equipped for electrodes. See Accessories section.
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 gen-
erating systems.
POWER MIG 200
B-3
B-3 OPERATION
6. Position the Readi-Reel so that it will rotate in a direction when feed-
PROCEDURE FOR CHANGING
ing so as to be de- reeled from top of the coil.
DRIVE AND IDLE ROLL SETS
7. Set one of the Readi-Reel inside cage wires on the slot in the retain-
1. Turn off the power source.
ing spring tab.
2. Release the pressure on the idle roll by swinging
8. Lower the Readi-Reel to depress the retaining spring and align the
the adjustable pressure arm down toward the back
other inside cage wires with the grooves in the molded adapter.
of the machine. Lift the cast idle roll assembly and
allow it to sit in an upright position..
9. Slide cage all the way onto the adapter until the retaining spring
"pops up" fully.
3. Remove the outside wire guide retaining plate by
loosening the two large knurled screws.
CAUTION
4. Twist the drive roll retaining mechanism to the
CHECK TO BE SURE THE RETAINING SPRING HAS FULLY
unlocked position as shown below and remove the
RETURNED TO THE LOCKING POSITION AND HAS SECURELY
drive roll. (See Figure A.4)
LOCKED THE READI-REEL CAGE IN PLACE. RETAINING SPRING
FIGURE A.4 MUST REST ON THE CAGE, NOT THE WELDING ELECTRODE.
-----------------------------------------------------------------------------------------------
10. To remove Readi-Reel from Adapter, depress retaining spring tab
with thumb while pulling the Readi-Reel cage from the molded
adapter with both hands. Do not remove adapter from spindle.
FIGURE B.1
LOCKED POSITION
UNLOCKED POSITION
5. Remove the inside wire guide plate.
6. Replace the drive and idle rolls and inside wire
guide with a set marked for the new wire size.
NOTE: Be sure that the gun liner and contact tip
are also sized to match the selected wire size.
7. Manually feed the wire from the wire reel, over the
drive roll groove and through the wire guide and
then into the brass bushing of the gun and cable
assembly.
To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300
8. Replace the outside wire guide retaining plate by
mm Diameter) or 14Lb.(6 Kg) Innershield Coils:
tightening the two large knurled screws. Reposition
the adjustable pressure arm to its original position
(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil Adapter must be
to apply pressure. Adjust pressure as necessary.
used).
WIRE REEL LOADING - READI-REELS, 1. Open the Wire Drive Compartment Door
SPOOLS OR COILS
2. Depress the Release Bar on the Retaining Collar and remove it
To Mount a 30 Lb. (14 kg) Readi-Reel Package
from the spindle.
(Using the Molded Plastic K363-P Readi-Reel
Adapter:) 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
1. Open the Wire Drive Compartment Door
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.
2. Depress the Release Bar on the Retaining Collar and remove it from
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
3. Place the Optional Adapter on the spindle
ring groove on the spindle.
4. Re-install the Retaining Collar. Make sure that the Release Bar “pops
TO START THE WELDER
up� and that the collar retainers fully engage the retaining ring groove
on the spindle. Turn the “Power Switch� switch to “ON�. This lights the red LED dis-
play lights. With the desired voltage and wire speed selected, oper-
5. Rotate the spindle and adapter so the retaining spring is at the 12
ate the gun trigger for welder output and to energize the wire feed
o'clock position.
motor.
POWER MIG 200
B-4 B-4
OPERATION
FEEDING WIRE ELECTRODE
MAKING A WELD
WARNING 1. Check that the electrode polarity is correct for the
process being used, then turn the power switch
When triggering, the electrode and drive mecha-
ON.
nism are electrically “hot� relative to work and
ground and remain “hot� several seconds after
2. Set desired arc voltage tap and wire speed for the
the gun trigger is released.
particular electrode wire, material type and thick-
ness, and gas (for GMAW) being used. Use the
Application Chart on the door inside the wire com-
NOTE: Check that drive rolls, guide plates and gun
partment as a quick reference for some common
parts are proper for the wire size and type being used.
welding procedures.
Refer to Table C.1 in Accessories section.
3. Press the trigger to feed the wire electrode through
1. Turn the Readi-Reel or spool until the free end of
the gun and cable and then cut the electrode within
the electrode is accessible.
approximately 3/8" (10 mm) of the end of the con-
tact tip [3/4" (20 mm) Outershield®].
2. While securely holding the electrode, cut off the
bent end and straighten the first six inches. (If the
4. If welding gas is to be used, turn on the gas supply
electrode is not properly straightened, it may not
and set the required flow rate (typically 25-35 CFH;
feed properly through the wire drive system).
12-16 liters/min).
3. Release the pressure on the idle roll by swinging
5. When using Innershield electrode, the gas nozzle
the adjustable pressure arm down toward the back
may be removed from the insulation on the end of
of the machine. Lift the cast idle roll assembly and
the gun and replaced with the gasless nozzle. This
allow it to sit in an upright position. Leave the outer
will give improved visibility and eliminate the possi-
wire guide plate installed. Manually feed the wire
bility of the gas nozzle overheating.
through the incoming guide bushing and through
the guide plates (over the drive roll groove). Push a
6. Connect work cable to metal to be welded. Work
sufficient wire length to assure that the wire has fed
clamp must make good electrical contact to the
into the gun and cable assembly without restriction.
work. The work must also be grounded as stated in
Reposition the adjustable pressure arm to its origi-
“Arc Welding Safety Precautions�.
nal position to apply pressure to the wire.
WARNING
4. Press gun trigger to feed the electrode wire
through the gun.
When using an open arc process, it is necessary
IDLE ROLL PRESSURE SETTING to use correct eye, head, and body protection.
The optimum idle roll pressure varies with type of
wire, wire diameter, surface conditions, lubrication,
7. Position electrode over joint. End of electrode
and hardness. As a general rule, hard wires may
may be lightly touching the work.
require greater pressure, and soft, or aluminum wire,
may require less pressure than the factory setting.
8. Lower welding helmet, close gun trigger, and
The optimum idle roll setting can be determined as
begin welding. Hold the gun so the contact tip to
follows:
work distance is about 3/8" (10 mm) [3/4" (20
1. Press end of gun against a solid object that is elec-
mm) for Outershield].
trically isolated from the welder output and press
the gun trigger for several seconds.
9. To stop welding, release the gun trigger and then
2. If the wire “birdnests�, jams or breaks at the drive
pull the gun away from the work after the arc
roll, the idle roll pressure is too great. Back the
goes out.
adjustment knob out 1/2 turn, run new wire through
gun, and repeat above steps.
10. When no more welding is to be done, close valve
3. If the only result was drive roll slippage, loosen the
on gas cylinder (if used), momentarily operate
adjustment knob on the conductor plate and pull
gun trigger to release gas pressure, and turn off
the gun cable forward about 6" (15 cm). There
POWER MIG 200.
should be a slight waviness in the expose wire. If
there is not waviness, the pressure is too low.
Tighten the adjustment knob 1/4 turn, reinstall the
gun cable and repeat the above steps. POWER MIG 200
B-5 B-5
OPERATION
INPUT LINE VOLTAGE VARIATIONS
AVOIDING WIRE FEEDING
High Line Voltage � Higher than rated input voltage
PROBLEMS
will result in output voltages higher than normal for a
Wire feeding problems can be avoided by observing
given tap setting. If your input line is high, you may
the following gun handling procedures:
want to select a lower voltage tap than given on the
recommended procedure chart.
1. Do not kink or pull cable around sharp corners.
Low Line Voltage � You may not be able to get
2. Keep the gun cable as straight as possible when
maximum output from the machine if the line voltage
welding or loading electrode through cable.
is less than rated input. The unit will continue to weld,
3. Do not allow dolly wheels or trucks to run over
but the output may be less than normal for a given tap
cables.
setting. If your input line is low, you may want to
4. Keep cable clean by following maintenance
select a higher voltage tap than given on the recom-
instructions.
mended procedure chart.
5. Use only clean, rust-free electrode. The Lincoln
electrodes have proper surface lubrication.
WIRE FEED OVERLOAD
6. Replace contact tip when the arc starts to become
PROTECTION
unstable or the contact tip end is fused or
The POWER MIG has solid state overload protection
deformed.
of the wire drive motor. If the motor becomes over-
7. Keep wire reel spindle brake tension to minimum
loaded, the protection circuitry turns off the wire feed
required to prevent excess reel over-travel which
speed and gas solenoid. Check for proper size tip,
may cause wire “loop-offs� from coil.
liner, and drive rolls, for any obstructions or bends in
8. Use proper drive rolls and wire drive idle roll pres-
the gun cable, and any other factors that would
sure for wire size and type being used.
impede the wire feeding. to resume welding, simply
FAN CONTROL pull the trigger. There is no circuit breaker to reset, as
the protection is done with reliable solid state elec-
The fan is designed to come on when input power is
tronics.
applied to the POWER MIG 200 and go off when
power is removed.
WELDING THERMAL OVERLOAD
PROTECTION
The POWER MIG 200 has built-in protective ther-
mostats that respond to excessive temperature. They
open the wire feed and welder output circuits if the
machine exceeds the maximum safe operating tem-
perature because of a frequent overload, or high
ambient temperature plus overload. The thermostats
automatically reset when the temperature reaches a
safe operating level and welding and feeding are
allowed again, when gun is retriggered.
Steel Thickness Wire Feed Speed/Voltage Tap Settings
Wire Dia. Gas Type WireType Polarity 18 gage 16 gage 14 gage 12 gage10gage 3/16 1/4 5/16 3/8 1/2
Outershield 3/4" ESO�
.035 75Ar/25CO2 OS71M DC+ 250/D 300/E 350/F 500/G *500/G
.035 100%CO2 OS71M DC+ 300/E 350/F 500/G
.045 75Ar/25CO2 OS71M 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 Mutiple Pass .035 & .045 NR-211 MP is only
� Electrical Stickout recommended for a maximun of 5/16"
POWER MIG 200
C-1 C-1
ACCESSORIES
DRIVE ROLL KITS ALTERNATIVE MAGNUM GMAW
GUN AND CABLE ASSEMBLIES
Refer to Table C.1 for various drive roll kits that are
available for the POWER MIG 200.The item in Bold is The following Magnum 250L gun and cable assem-
supplied standard with the POWER MIG 200. blies are separately available for use with the POWER
MIG 200. Each is rated 200 amps 60% duty cycle and
is equipped with the integrated connector, twist-lock
Wire Size Drive Roll Kit
trigger connector, fixed nozzle and insulator, and
includes a liner, diffuser, and contact tips for the wire
.023�-.030� (0.6-0.8 mm) KP1696-030S
Solid
sizes specified:
.035� (0.9 mm) KP1696-035S
Steel
.045� (1.2 mm) KP1696-045S
English Wire Metric Wire
Length Part No. Size Size
.035� (0.9 mm) KP1697-035C
Cored 10' (3.0 m) K533-1
.045� (1.2 mm) KP1697-045C 12' (3.6 m) K533-2 .035 � .045" 0.9 � 1.2 mm
15' (4.5 m) K533-3
Aluminum 3/64� (1.2 mm) KP1695-3/64A 10' *3.0 m) K533-4
12' (3.6 m) K533-5 .025 � .030" 0.6 � 0.8 mm
TABLE C.1 15' (4.5 m) K533-6
3/64" (1.2 mm) ALUMINUM
FEEDING KIT (K1703-1) MAGNUM GUN CONNECTION KIT
(Optional K466-6)
This kit helps push feeding aluminum through stan-
dard machine feeder and gun. It provides gun and Using the optional K466-6 Magnum Connection kit for
wire drive conversion parts to weld with 3/64" (1.2 the POWER MIG permits use of standard Magnum
mm) aluminum wire. 5356 alloy aluminum wire is rec- 200, 300 or 400 gun and cable assemblies.
ommended for best push feeding performance.
Kit includes drive rolls and wire guide plate for the
wire drive, liner and two contact tips for the gun, along
SPOOL GUN AND ADAPTER KIT
with installation instructions.
(K1809-1)
The K1809-1includes the Magnum 250SG Spool gun
K363P READI-REEL ADAPTER and the adapter kit for connecting the spool gun to the
Power MIG 200.
The K363P Readi-Reel Adapter mounts to the 2" spin-
dle. It is needed to mount the 22-30 lb. Readi-Reels. The Adapter Kit provides toggle switch selection
between the machine’s use with its feeder gun or the
DUAL CYLINDER MOUNTING KIT spool gun for same polarity welding with different wire
(K1702-1) and gas processes.
The kit includes a spool gun adapter module assem-
Permits stable side-by-side mounting of two full size
bly with a single connecting plug and trigger switch, a
(9" dia. x 5' high) gas cylinders with “no lift� loading.
rear gas inlet, fitting hose, solenoid valve assembly,
Simple installation and easy instructions provided.
and mounting hardware with installation and operation
Includes upper and lower cylinder supports, wheel
instructions.
axles and mounting hardware.
WARNING
Remove all input power to the POWER MIG 200
before installing the Spool Gun and Kit.
POWER MIG 200
C-2 C-2
ACCESSORIES
MAKING A WELD WITH THE SPOOL GUN
ADAPTER KIT AND SPOOL GUN
INSTALLED
CAUTION
In either toggle switch position, closing either gun
trigger will cause the electrode of both guns to be
electrically “HOT�. Be sure unused gun is posi-
tioned so electrode or tip will not contact metal
case or other metal common to work.
1. Setting spool gun selector switch to the “Normal�
position and pulling the trigger for the built-in feed-
er gun.
� 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 deter-
mine the final settings.
5. To return to normal POWER MIG 200 welding,
release the spool gun trigger set spool gun selector
switch to normal and reset feeder gun voltage pro-
cedure setting if necessary.
POWER MIG 200
D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS CONTACT TIP AND GAS NOZZLE
INSTALLATION
WARNING 1. Choose the correct size contact tip for the elec-
trode being used (wire size is stenciled on the side
of the contact tip) and screw it snugly into the gas
ELECTRIC SHOCK can kill.
diffuser.
� Have an electrician install and
service this equipment.
2. Screw the appropriate fixed gas nozzle fully onto
� Turn the input power off at the the diffuser. Either the standard .50" (12.7 mm)
fuse box before working on flush nozzle or other optional flush or recessed
equipment (spray arc) nozzle sizes may be used. (See Table
D.2 in this section.)
� Do not touch electrically hot
parts.
3. If using optional adjustable slip-on nozzles, see
Table D.2 in this section.
GENERAL MAINTENANCE
� Be sure the nozzle insulator is fully screwed
In extremely dusty locations, dirt may clog the air pas- onto the gun tube and does not block the gas
sages causing the welder to run hot. Blow dirt out of holes in the diffuser.
the welder with low-pressure air at regular intervals to
eliminate excessive dirt and dust build-up on internal � Slip the appropriate gas nozzle onto the nozzle
parts. insulator. Either a standard .50" (12.7 mm) or
optional .62" (15.9 mm) I.D. slip-on gas nozzle
The fan motors have sealed ball bearings which may be used and should be selected based on
require no service. the welding application.
* Adjust the gas nozzle as appropriate for the
DRIVE ROLLS AND GUIDE PLATES GMAW process to be used. Typically, the con-
tact tip end should be flush to .12" (3.2 mm)
extended for the short-circuiting transfer
After every coil of wire, inspect the wire drive mecha-
process and .12" (3.2 mm) recessed for spray
nism. Clean it as necessary by blowing with low pres-
transfer.
sure compressed air. Do not use solvents for cleaning
the idle roll because it may wash the lubricant out of
the bearing. All drive rolls are stamped with the wire
GUN TUBES AND NOZZLES
sizes they will feed. If a wire size other than that
stamped on the roll is used, the drive roll must be
1. Replace worn contact tips as required.
changed.
2. Remove spatter from inside of gas nozzle and
For instructions on replacing or changing drive roll,
from tip after each 10 minutes of arc time or as
see “Wire Drive Rolls� in Operation section.
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 con-
tact tip from the gun. Using an air hose and only par-
tial pressure, gently blow out the cable liner from the
gas diffuser end.
POWER MIG 200
D-2
D-2 MAINTENANCE
CAUTION 4. Insert a new untrimmed liner into the connector
end of the cable. Be sure the liner bushing is sten-
cilled appropriately for the wire size bing used.
Excessive pressure at the start may cause the dirt
to form a plug.
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
Flex the cable over its entire length and again blow
installed onto the end of the gun tube.
out the cable. Repeat this procedure until no further
dirt comes out. If this has been done and feed prob-
6. With the gas diffusor still removed from the gun
lems are experienced, try liner replacement, and refer
tube, be sure the cable is straight, and then trim
to trouble shooting section on rough wire feeding.
the liner to the length shown in Figure D.1.
Remove any burrs from the end of the liner.
LINER REMOVAL AND REPLACE-
MENT 7. Screw the gas diffuser onto the end of the gun tube
and securely tighten. Be sure the gas diffuser is
NOTE: Changing the liner for a different wire size
correct for the liner being used. (See table and dif-
requires replacement of the gas diffuser per Table D.1
fuser stencil.)
to properly secure the different liner.
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.
TABLE D.1
Fixed Adjustable
Nozzle Nozzle
Replacement Size Stencilled Gas Diffuser Gas Diffuser FIGURE D.1
Diameter of Liner Part on End of Part No. Part No.
Electrodes Used Number Liner Bushing (and Stencil) (and Stencil)
SET SCREW
.025-.030" Steel M16087-2 .030 (0.8 mm) S19418-3 S19418-2
(0.6-0.8 mm) BRASS CABLE CONNECTOR
1-1/4"
(31.8mm)
.035-.045" Stee M16087-1 .045 (1.2 mm) S19418-3 S19418-1 LINER
(0.9-1.2 mm) TRIM
LENGTH
3/64" Aluminum M17714-1 3/64" (1.2 mm) S19418-3 S19418-1
(1.2 mm)
SET SCREW
LINER REMOVAL, INSTALLATION AND TRIMMING GAS DIFFUSER
INSTRUCTIONS FOR NOZZLE INSULATOR (IF USED)
MAGNUM 250L GAS NOZZLE
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
CAUTION
installed in another gun unless it can meet the liner
cutoff length requirement. Liners are shipped with the
This screw should only be gently tightened.
jacket of the liner extended the proper amount.
Overtightening will split or collapse the liner and
cause poor wire feeding.
1. Remove the gas nozzle and nozzle insulator, if
used, to locate the set screw in the gas diffuser
which is used to hold the old liner in place. Loosen
the set screw with a 5/64" (2.0 mm) Allen wrench.
2. Remove the gas diffuser from the gun tube.
3. Lay the gun and cable out straight on a flat surface.
Loosen the set screw located in the brass connec-
tor at the feeder end of the cable and pull the liner
out of the cable.
POWER MIG 200
D-3 MAINTENANCE D-3
TABLE D.2
GUN HANDLE DISASSEMBLY
ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS
FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES
The internal parts of the gun handle may be
inspected or serviced if necessary. English Metric
Description Part No. Size Size
The gun handle consists of two halves that are CABLE LINER
held together with a collar on each end. To For 15' (4.5 m) or M16087-2 .025 � .030" 0.6 � 0.8 mm
shorter Cable M16087-1 .035 � .045" 0.9 � 1.2 mm
open up the handle, turn the collars approxi-
M17714-1 3/64" 1.2 mm
mately 60 degrees counterclockwise (the same
(Alum. wire) (Alum. wire)
direction as removing a right hand thread) until
the collar reaches a stop. Then pull the collar CONTACT TIPS
off the gun handle. If the collars are difficult to Standard Duty S19391-6 .025" 0.6 mm
S19391-7 .030" 0.8 mm
turn, position the gun handle against a corner,
S19391-1 * .035" 0.9 mm
place a screwdriver against the tab on the col-
S19391-2 .045" 1.2 mm
lar and give the screwdriver a sharp blow to Heavy Duty S19392-1 .035" 0.9 mm
turn the collar past an internal locking rib. 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
Counterclockwise
M16081-2 * 1/2" 12.7 mm
âž?
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
* Included with POWER MIG 200
� Requires S19418-1 Gas Diffuser Assembly.
POWER MIG 200
E-1
E-1 TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE� lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER MIG 200
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical 1. Contact your Local Lincoln
Damage is Evident Authorized Field Service Facility.
There is no wire feed or open cir- 1 The gun trigger or cable may be
cuit voltage when the gun trigger is faulty. Check or replace gun
pulled. Input power is applied to assembly.
POWER MIG 200. 2. The thermal protection circuit
may be activated. If this is the
case allowing the machine to
cool will clear the error condition.
3. Make sure input voltage is cor-
rect and matches nameplate rat-
ing and reconnect panel configu-
ration.
4. If spool gun option kit is in
stalled, check to see that it is set
to “Normal� if pulling the gun trig-
ger associated with built in feed-
er, and “Spool Gun� if pulling
spool gun trigger. If all recommended possible areas
of misadjustment have been
Output voltage and wire feed is pre- 1. Remove gun assembly from checked and the problem persists,
sent when gun trigger is not pulled machine. If problem is solved Contact your local Lincoln
(not activated). gun assembly is faulty. Repair or Authorized Field Service Facility.
replace.
2. If problem persists when gun
assembly is removed from
machine then the problem is
within the POWER MIG 200.
Machine output is low. Welds are 1. Check input voltage. Make sure
“cold�, weld bead is rounded or input voltage matches name-
bumped up demonstrating poor plate rating and reconnect panel
wetting into plate. configuration.
2. Make sure settings for wire feed
speed and voltage are correct
for process being used.
3. Make sure output polarity is cor-
rect for process being used.
4. Check welding cables and gun
assembly for loose or faulty con-
nections.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
POWER MIG 200
E-3
E-3 TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT COURSE OF ACTION
OUTPUT PROBLEMS
1. Poor arc striking with electrode 1. Make sure settings for wire feed
sticking or blasting off. speed and voltage are correct
for process being used.
2. The gas shielding may be If all recommended possible areas
improper for process being used. of misadjustment have been
3. Check imput line voltage to be checked and the problem persists,
with in machines recommended Contact your local Lincoln
rating range. Authorized Field Service Facility.
4. Check that the machine recon-
nect panel is configured properly
for the applied voltage.
FEEDING PROBLEMS
POSSIBLE AREAS OF RECOMMENDED
PROBLEMS
MISADJUSTMENT(S) COURSE OF ACTION
(SYMPTOMS)
1. The gun cable may be kinked or twisted.
1. Rough wire feeding or wire will
not feed but drive rolls are turn- 2. The wire may be jammed in the gun
ing. cable, or gun cable may be dirty.
3. Check drive roll tension and
position of grooves.
4. Check for worn or loose drive rolls.
5. The electrode may be rusty or dirty.
6. Check for damaged or incorrect
contact tip.
7. Check wire spindle for ease of
rotation and adjust break ten-
If all recommended possible areas
sion knob if necessary.
of misadjustment have been
8. Check that the gun is pushed all checked and the problem persists,
the way into gun mount and Contact your local Lincoln
properly seated. Authorized Field Service Facility.
1. Check the wire feed drive rolls
1. The wire feed stops while weld-
and motor for smooth operation.
ing. When trigger is released
and pulled again the wire feed 2. Check for restrictions in the wire
starts. feed path. Check the gun and
cable for restrictions.
3. Make sure gun liner and tip are
correct for wire size being used.
4. Make sure drive rolls and guide plates
are clean and are the correct size.
5. Check spindle for ease of rotation.
1. No control of wire feed speed. 1. The wire feed speed control may
Other machine functions are nor- be dirty. Rotate several times
mal. and check if problem is resolved.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
POWER MIG 200
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
GAS FLOW PROBLEMS
Gas does not flow when gun trigger 1. Make sure gas supply is con-
is pulled. nected properly and turned “on�.
2. If the gas solenoid does actuate
(click) when the gun trigger is If all recommended possible areas
pulled there may be a restriction of misadjustment have been
in the gas supply line. checked and the problem persists,
Contact your local Lincoln
3. The gun cable assembly may be Authorized Field Service Facility.
faulty. Check or replace.
4. If gas solenoid does not operate
when gun trigger is pulled the
problem is within the POWER
MIG 200.
5. Make sure the gun is pushed all
the way into gun mount and is
properly seated.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
POWER MIG 200
F-1
POWER MIG 200 (208/230V)
GENERAL INFORMATION NOTES:
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF
ELECTRICAL SYMBOLS PER E1537 CONTROL BOARD
IMMEDIATE AND FUTURE APPLICATIONS.
CAVITY NUMBERING SEQUENCE COLOR CODE N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIVE�. TO CHANGE POLARITY, TURN
(COMPONENT SIDE OF P.C. BOARD) B- BLACK THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK
W- WHITE STUD.
R- RED
1 8 1
3
1
U- BLUE
J1 J2 J3 101A 1
16
9 4 6
2 INDICATES CONNECTOR CAVITY No. 102A 2
RECTIFIER
TRANSFORMER ASSEMBLY
THERMOSTAT
THERMOSTAT 103A 3
** CAVITY
104A 104A
104B
104C 4
NUMBERING SEQUENCE
105A 5
(NON-LEAD SIDE OF CONNECTOR)
J4 (TRIGGER,
106A 6
TACHOMETER,
MOTOR SIDE)
7
107A
1 4
3
1
108A 8
PA
J1
103A
4 6
5 8 109A 9
R2
110A 10
109A 111A 11
113A
112A 12
WIRE FEED
SPEED
113A 13
14
114A
108A
15
115A
116A 16
X9 X10
114A
106A J5 PA
116A
BAFFLE
MOUNTED
-
1 1
116B **
RECTIFIER
GAS
DIODE 2 2
104C
BRIDGE SOLENOID
X10 105A 3 3
116B
+
106C
27.8V 106C 4 4
107A
106B
5 5
104D
106B
6 6
105B
X9
X8 G JUMPER PLUG
INSTALLED FOR
X7 F
H1 NON-SPOOL GUN
L2
L1 SINGLE PHASE GUN OPERATION
X6 E J4
TRIGGER
BRIDGE **
H2
H3 H4 L1 L2 X5 D 1
RECTIFIER 1 104D
324
H5
TO SINGLE PHASE
111A
325 2
CONTACTOR 2
SUPPLY LINE X4 C
H2
208V
230V 3 3 115A
R
H1 H4
POWER MIG 200
W 4
X3 B U 4 101A
B 5
TAP SELECTOR 102A
B X2 A SWITCH
H1 6
RECONNECT H3
PANEL B 7 105B
X1
LINE
SWITCH POWER W 8 112A
G
S1 TRANSFORMER
TO GROUND PER
NATIONAL ELECTRICAL 1
CODE
2
3
J2
WIRING DIAGRAMS
4
B
5
6
+
MOTOR/
P.M. GEARBOX
H1B H5 R T -
A
U C
H
B
FAN
TO
W
MOTOR WORK
1
FOR SPOOL GUN OPTION
J3
2
40 OHMS
R1
C1 C2
C1 AND C2 50 W
31,000 MFD
50V + +
OUTPUT
CHOKE
10- 2000
L11424
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-1
F-2 F-2
DIMENSION PRINT
M19231
3-00F
POWER MIG 200
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With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
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G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
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