Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
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 andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii; WELDING and CUTTING
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. 93 POWER MIG 215 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 LʼArc 1. Proteg...
Page 6 - Please Examine Carton and Equipment For Damage Immediately
v v Thank Y You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manu...
Page 7 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
vi vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page ________________________________________________________________________ Installation .......................................................................................................Section A Technical Specifications ..........................
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS – POWER MIG 215
A-1 A-1 INSTALLATION 75°C Copper Wire 75°C Copper Wire Input Ampere in Conduit in Conduit Input Voltage/ Fuse or Breaker Rating On AWG (IEC) Sizes AWG (IEC) Sizes (For lengths (For lengths Frequency (Hz) Size (Super Lag) Nameplate up to 100 ft.) exceeding 100 ft.) 208/50/60 60 45A 10 (6 mm 2 ) 8 (10...
Page 10 - SAFETY PRECAUTIONS; Before starting the installation, check with the local; UNCRATING THE POWER MIG 215
A-2 A-2 INSTALLATION Read entire installation section before startinginstallation. SAFETY PRECAUTIONS POWER MIG 215 INPUT POWER, GROUNDING ANDCONNECTION DIAGRAMS 1. Before starting the installation, check with the local p o w e r c o m p a n y i f t h e r e i s a n y q u e s t i o n a b o u twhether...
Page 11 - FIGURE A.2 — Receptacle Diagram; FIGURE A.1 — Dual Voltage Machine Input Connections; OUTPUT POLARITY CONNECTIONS
3. The 208/230 volt 50/60 Hz model POWER MIG is shipped with a 7 ft.(2.1m). input cable and plugconnected to the welder. 4. Using the instructions in Figure A.2, have a quali- fied electrician connect a receptacle (CustomerSupplied) or cable to the input power lines and thesystem ground per the U.S....
Page 13 - OPERATION; ELECTRIC SHOCK can kill.
B-1 B-1 OPERATION R e a d e n t i r e O p e r a t i o n s e c t i o n b e f o r eoperating the POWER MIG 215. ELECTRIC SHOCK can kill. • D o n o t t o u c h e l e c t r i c a l l y l i v e parts or electrode with skin or wetclothing. Insulate yourself fromwork and ground. • A l w a y s w e a r d r y...
Page 14 - Place the lever in the; Voltage Control —; Seven voltage tap selections; Wire Speed Control — T; his controls the wire feed
B-2 B-2 OPERATION PRODUCT DESCRIPTION The POWER MIG™ 215 is a complete semiautomaticDC voltage arc welding machine built to meet NEMAspecifications. It combines a tapped transformer volt-age power source with a constant speed wire feederto form a reliable robust performance welding system.A simple c...
Page 15 - TO START THE WELDER
B-3 B-3 OPERATION PROCEDURE FOR CHANGINGDRIVE 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 backof the machine. Lift the cast idle roll assembly andallow it to sit in an upright position.. 3. Remove t...
Page 16 - FEEDING WIRE ELECTRODE; IDLE ROLL PRESSURE SETTING
B-4 B-4 OPERATION FEEDING WIRE ELECTRODE When triggering, the electrode anddrive mechanism are electrically “hot”r e l a t i v e t o w o r k a n d g r o u n d a n dremain “hot” several seconds afterthe gun trigger is released. ------------------------------------------------------------------------N...
Page 17 - • When using an open arc process, it
B-5 B-5 OPERATION 3. Press the trigger to feed the wire electrode through the gun and cable. For solid wire cut the electrodewithin approximately 3/8" (10 mm) of the end of thecontact tip [3/4" (20 mm) for Outershield ® ]. 4. When welding with gas, turn on the gas supply and set the required...
Page 18 - FAN CONTROL; High Line Voltage; W E L D I N G T H E R M A L O V E R L O A D; Wire Feed Speed/Voltage Tap Settings
B-6 B-6 OPERATION 9. When no more welding is to be done, close valveon gas cylinder (if used), momentarily operate gunt r i g g e r t o r e l e a s e g a s p r e s s u r e , a n d t u r n o f fPOWER MIG 215. NOTE: When using Innershield electrode, the gas nozzle may be removed from the insulation on...
Page 19 - ACCESSORIES; DRIVE ROLL KITS; Bold
C-1 C-1 ACCESSORIES DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that areavailable for the POWER MIG 215.The item in Bold is supplied standard with the POWER MIG 215. TABLE C.1 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1) This kit helps push feeding aluminum through stan-dard ...
Page 20 - CAUTION
MAKING A WELD WITH THE SPOOL GUNADAPTER KIT AND SPOOL GUNINSTALLED In either toggle switch position, closing either guntrigger will cause the electrode of both guns to beelectrically “HOT”. Be sure unused gun is posi-tioned so electrode or tip will not contact metalcase or other metal common to work...
Page 21 - MAINTENANCE; GUN TUBES AND NOZZLES; • Have an electrician install and; GENERAL MAINTENANCE
D-1 D-1 MAINTENANCE • Be sure the nozzle insulator is fully screwedonto the gun tube and does not block the gasholes in the diffuser. • Slip the appropriate gas nozzle onto the nozzleinsulator. Either a standard .50" (12.7 mm) oroptional .62" (15.9 mm) I.D. slip-on gas nozzlemay be used and ...
Page 22 - different
D-2 D-2 MAINTENANCE 7. Screw the gas diffuser onto the end of the gun tube and securely tighten. Be sure the gas diffuser iscorrect for the liner being used. (See table and dif-fuser stencil.) 8. Tighten the set screw in the side of the gas diffuser against the cable liner using a 5/64" (2.0 mm)...
Page 23 - GUN HANDLE DISASSEMBLY; ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS
D-3 D-3 MAINTENANCE GUN HANDLE DISASSEMBLY The internal parts of the gun handle may beinspected or serviced if necessary. The gun handle consists of two halves that areheld together with a collar on each end. Toopen up the handle, turn the collars approxi-mately 60 degrees counterclockwise (the same...
Page 24 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
E-1 E-1 TROUBLESHOOTING POWER MIG 215 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. CAUTION This Troubleshooting ...
Page 25 - OUTPUT PROBLEMS; Observe all Safety Guidelines detailed throughout this manual
E-2 E-2 TROUBLESHOOTING PROBLEMS(SYMPTOMS) Major Physical or ElectricalDamage is Evident There is no wire feed or open cir-cuit voltage when the gun trigger ispulled. Input power is applied toPOWER MIG 215. Output voltage and wire feed is pre-sent when gun trigger is not pulled(not activated). Machi...
Page 26 - FEEDING PROBLEMS
E-3 E-3 TROUBLESHOOTING PROBLEMS(SYMPTOMS) Poor arc striking with electrodesticking or blasting off. Auxiliary receptacle is “dead” - noauxiliary voltage. Rough wire feeding or wire will notfeed but drive rolls are turning. POSSIBLE CAUSE 1. Make sure settings for wire feed speed and voltage are cor...
Page 27 - GAS FLOW PROBLEMS
E-4 E-4 TROUBLESHOOTING PROBLEMS(SYMPTOMS) The wire feed stops while welding.When trigger is released andpulled again the wire feed starts. No control of wire feed speed.Other machine functions are nor-mal. Gas does not flow when gun triggeris pulled. POSSIBLE CAUSE 1. Check the wire feed drive roll...
Page 28 - WIRING DIAGRAMS
F-1 F-1 WIRING DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram 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 ...
Page 29 - Enhanced Diagram
F-2 F-2 WIRING DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram 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 ...
Page 30 - DIMENSION PRINT
Page 31 - NOTES