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
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 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 seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
Thank 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 manual and...
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 ........................................................................................A-1Safet...
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS – POWER MIG 200
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 36 10 (6 mm 2 ) 8 (10 ...
Page 10 - Before starting the installation, check with the local; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
A-2 A-2 INSTALLATION 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 your power supply is adequate for the volt-age, amperes, phase, and frequency specified onthe ...
Page 11 - FIGURE A.3 — Receptacle Diagram; OUTPUT POLARITY CONNECTIONS; Dual Voltage Machine Input Connections; Technical Specifications; Receptacle Diagram
A-3 A-3 INSTALLATION POWER MIG 200 FIGURE A.3 — Receptacle Diagram CONNECT TO A SYSTEMGROUNDING WIRE. SEETHE UNITED STATESNATIONAL ELECTRICALCODE AND/OR LOCALCODES FOR OTHERDETAILS AND MEANS FORPROPER GROUNDING. CONNECT TO HOT WIRESOF A THREE-WIRE, SINGLEPHASE SYSTEM OR TO ONEPHASE OF A TWO ORTHREE ...
Page 12 - cracking
GUN AND CABLE INSTALLATION The Magnum 250L gun and cable provided with thePOWER MIG 200 is factory installed with a liner for.035-.045" (0.9-1.2 mm) electrode and an .035" (0.9mm) contact tip. Be sure that the contact tip, liner, anddrive rolls all match the size of the wire being used. Turn...
Page 13 - OPERATION
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 200. 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 p a r t s o r e l e c t r o d e w i t h s k i n o rw e t c l o t h i n g . I n s u l a t e y o u r s e l ffrom ...
Page 14 - The POWER MIG; This controls the wire feed; speed from 50
B-2 B-2 OPERATION PRODUCT DESCRIPTION The POWER MIG ™ 200 is a complete semiautomatic DC 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...
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
B-4 B-4 OPERATION FEEDING WIRE ELECTRODE When triggering, the electrode and drive mecha-nism are electrically “ hot ” relative to work and ground and remain “ hot ” several seconds after the gun trigger is released. NOTE: Check that drive rolls, guide plates and gunparts are proper for the wire size...
Page 17 - 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; Steel Thickness Wire Feed Speed/Voltage Tap Settings; Wire Dia. Gas Type WireType
B-5 B-5 OPERATION AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observingthe following gun handling procedures: 1. Do not kink or pull cable around sharp corners.2. Keep the gun cable as straight as possible when welding or loading electrode through cable. 3. Do not allow do...
Page 18 - ACCESSORIES; DRIVE ROLL KITS
C-1 C-1 ACCESSORIES DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that areavailable for the POWER MIG 200.The item in Bold issupplied standard with the POWER MIG 200. TABLE C.1 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1) This kit helps push feeding aluminum through stan-dard m...
Page 19 - HOT; CAUTION
C-2 C-2 ACCESSORIES 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 ot...
Page 20 - MAINTENANCE; GUN TUBES AND NOZZLES; Have an electrician install and; GENERAL MAINTENANCE
D-1 D-1 MAINTENANCE CONTACT TIP AND GAS NOZZLEINSTALLATION 1. Choose the correct size contact tip for the elec- trode being used (wire size is stenciled on the sideof the contact tip) and screw it snugly into the gasdiffuser. 2. Screw the appropriate fixed gas nozzle fully onto the diffuser. Either ...
Page 22 - 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 23 - TROUBLESHOOTING; Look under the column labeled; HOW TO USE TROUBLESHOOTING GUIDE
E-1 E-1 TROUBLESHOOTING POWER MIG 200 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting G...
Page 24 - 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 200. Output voltage and wire feed is pre-sent when gun trigger is not pulled(not activated). Machi...
Page 25 - FEEDING PROBLEMS
E-3 E-3 TROUBLESHOOTING PROBLEMS(SYMPTOMS) 1. Poor arc striking with electrode sticking or blasting off. POSSIBLE AREAS OFMISADJUSTMENT 1. Make sure settings for wire feed speed and voltage are correctfor process being used. 2. The gas shielding may be improper for process being used. 3. Check imput...
Page 26 - GAS FLOW PROBLEMS
E-4 E-4 TROUBLESHOOTING PROBLEMS(SYMPTOMS) Gas does not flow when gun triggeris pulled. POSSIBLE AREAS OFMISADJUSTMENT(S) 1. Make sure gas supply is con- nected properly and turned “ on ” . 2. If the gas solenoid does actuate (click) when the gun trigger ispulled there may be a restrictionin the gas...
Page 27 - WIRING DIAGRAMS; POW
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 28 - DIMENSION PRINT
Page 29 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th Edition The Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P...
Page 30 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...