Lincoln Electric POWER MIGTM 200 IM693 Operator's Manual

Lincoln electric welder user manual

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Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However, your

overall safety can be increased by

proper installation ... and thought-

ful operation on your part. DO

NOT INSTALL, OPERATE OR

REPAIR THIS EQUIPMENT

WITHOUT

READING

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:

• 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

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POWER MIG

For use with machine Code Numbers

THIS

OPERATOR'S MANUAL

• World's Leader in Welding and Cutting Products •

200

™

10564

IM693

June, 2002

Table of Contents

Troubleshooting

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Summary of Contents for Lincoln Electric POWER MIGTM 200 IM693

Page 1 POWER MIG 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...
Page 2: California Proposition 65 Warnings
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.
Page 3: Electric Shock Can Kill
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.
Page 4 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.
Page 5 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
Page 7: Table Of Contents
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...
Page 8 MASTER TABLE OF CONTENTS FOR ALL SECTIONS (cont.) 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...
Page 9: Installation
TECHNICAL SPECIFICATIONS – POWER MIG 200 Standard Voltage/Frequency 208/230/50/60 Hz Duty Cycle Welding Current Range 30 – 200 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage/ Fuse or Breaker Frequency (Hz) Size (Super Lag) 208/50/60 230/50/60 Height 31.79 in 808 mm Wire Speed INSTALLATION...
Page 10: Installation
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...
Page 11: Output Polarity Connections
A green wire in the input cable connects this contact to the frame of the welder. This ensures proper grounding of the welder frame when the welder plug is inserted into a grounded receptacle.
Page 12: Gun And Cable Installation
Be sure that the contact tip, liner, and drive rolls all match the size of the wire being used. WARNING Turn the welder power switch off before installing gun and cable. 1. Lay the cable out straight.
Page 13: Operation
Read entire Operation section before operating the POWER MIG 200. Observe all safety information throughout this manual. OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. •...
Page 14: Product Description
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 volt- age 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...
Page 15: Procedure For Changing Drive And Idle Roll Sets
Turn the “Power Switch” switch to “ON”. This lights the red LED dis- play lights. With the desired voltage and wire speed selected, oper- ate the gun trigger for welder output and to energize the wire feed motor. POWER MIG 200 CAUTION FIGURE B.1...
Page 16: Feeding Electrode
The optimum idle roll setting can be determined as follows: 1. Press end of gun against a solid object that is elec- trically 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.
Page 17: Avoiding Wire Feeding Problems
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.
Page 18: Accessories
DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that are available for the POWER MIG 200.The item in Bold is supplied standard with the POWER MIG 200. Wire Size .023”-.030” (0.6-0.8 mm) Solid .035” (0.9 mm) Steel .045”...
Page 19: Making A Weld With The Spool Gun Adapter Kit And Spool Gun Installed
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.
Page 20: Safety Precautions
GENERAL MAINTENANCE In extremely dusty locations, dirt may clog the air pas- sages 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.
Page 21: Liner Removal And Replace- Ment
CAUTION Excessive pressure at the start may cause the dirt to form a plug. Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out. If this has been done and feed prob- lems are experienced, try liner replacement, and refer to trouble shooting section on rough wire feeding.
Page 22: Gun Handle Disassembly
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 approxi- mately 60 degrees counterclockwise (the same direction as removing a right hand thread) until the collar reaches a stop.
Page 23: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE 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.
Page 24: Troubleshooting
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. TROUBLESHOOTING POSSIBLE AREAS OF...
Page 25 Other machine functions are nor- mal. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
Page 26 Gas does not flow when gun trigger is pulled. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
Page 27: Wiring Diagrams
WIRING DIAGRAMS OPTION SPOOL POWER MIG 200...
Page 28 DIMENSION PRINT POWER MIG 200...
Page 29 _______________________________________________ _______________________________________________ Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month Year BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Price Code $5.00 $15.00 $4.50 $5.00...
Page 30 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● German ● WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
Page 31 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
Page 32 • 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...

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