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SVM157-A
October 2001
™
POWER MIG 200
For use with machines having Code Numbers:
10564
10584
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before yo
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains chem- are known to the State of California to cause cancer, icals known to the State of California to cause cancer, birth defects, and other reproductive harm. birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free gloves open arc welding. Headshield and filter lens to insulate hands. should conform to ANSI Z87. I standards. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode 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 ho
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffe- Pour votre propre protection lire et observer toutes les instructions et ment et un risque d’incendie. les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: 8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratiqu
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v v RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section A Section A TABLE OF CONTENTS - INSTALLATION SECTION - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Uncrating the Power MIG 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Location . . . . . .
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS – POWER MIG 200 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current @ 150 Amp Rated Output Input Current @ 150 Amp Rated Output 208/230/60 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 C
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A-3 A-3 INSTALLATION Read entire installation section before starting INPUT POWER, GROUNDING AND installation. CONNECTION DIAGRAMS SAFETY PRECAUTIONS WARNING WARNING ELECTRIC SHOCK can kill. ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as • Only qualified personnel should perform output terminals or internal wiring. this installation. • All input power must be electrically dis- • Only personnel that have read and under- connected before proceeding. stood the POWER MIG 200
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A-4 A-4 INSTALLATION FIGURE A.1 — Dual Voltage Machine Input Connections 4. Using the instructions in Figure A.3, have a quali- 3. The 208/230 volt 60 Hz model POWER MIG is fied electrician connect a receptacle (Customer shipped with a 7 ft. input cable and plug connected Supplied) or cable to the input power lines and the to the welder. system ground per the U.S. National Electrical Code and any applicable local codes. See The 230/460/575 volt 60 Hz model is not equipped “Technical Specificatio
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A-5 A-5 INSTALLATION FIGURE A.2 — Triple Voltage Machine Input Connections OUTPUT POLARITY CONNECTIONS FIGURE A.3 — Receptacle Diagram The welder, as shipped from the factory, is connected CONNECT TO A SYSTEM for electrode positive (+) polarity. This is the normal GROUNDING WIRE. SEE THE UNITED STATES polarity for GMA welding. NATIONAL ELECTRICAL CODE AND/OR LOCAL If negative (–) polarity is required, interchange the con- CODES FOR OTHER DETAILS AND MEANS FOR nection of the two cables located in
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A-6 A-6 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 The Magnum 250L gun and cable provided with the clean cloth. POWER MIG 200 is factory installed with a liner for .035-.045" (0.9-1.2 mm) electrode and an .035" (0.9 DO NOT ATTACH THE REGULATOR IF OIL, mm) contact tip. Be sure that the contact tip, liner, and GREASE OR DAMAGE IS PRESENT! Inform your drive
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Section B Section B TABLE OF CONTENTS - OPERATION SECTION - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . B-3 Welding Capability . . . . . .
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B-2 B-2 OPERATION 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 clo
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ON OFF B-3 B-3 OPERATION PRODUCT DESCRIPTION LIMITATIONS The output voltage/current of the POWER MIG 200 is The POWER MIG™ 200 is a complete semiautomatic subject to vary if the input power to the machine varies, DC voltage arc welding machine built to meet NEMA due to its tapped transformer power topology. In some specifications. It combines a tapped transformer volt- cases an adjustment of WFS preset and/or voltage tap age power source with a constant speed wire feeder to selection may be re
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B-4 B-4 OPERATION 7. Set one of the Readi-Reel inside cage wires on the slot in the retain- PROCEDURE FOR CHANGING ing spring tab. DRIVE AND IDLE ROLL SETS 8. Lower the Readi-Reel to depress the retaining spring and align the 1. Turn off the power source. other inside cage wires with the grooves in the molded adapter. 9. Slide cage all the way onto the adapter until the retaining spring "pops 2. Release the pressure on the idle roll by swinging the up" fully. adjustable pressure arm down towa
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B-5 B-5 OPERATION FEEDING WIRE ELECTRODE MAKING A WELD 1. Check that the electrode polarity is correct for the WARNING 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 the 2. Set desired arc voltage tap and wire speed for the gun trigger is released. particular electrode wire, material type and thick- ness, and gas (for GMAW) being used. Use the Applica
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B-6 B-6 OPERATION AVOIDING WIRE FEEDING INPUT LINE VOLTAGE VARIATIONS PROBLEMS High Line Voltage — Higher than rated input voltage Wire feeding problems can be avoided by observing will result in output voltages higher than normal for a the following gun handling procedures: given tap setting. If your input line is high, you may want to select a lower voltage tap than given on the 1. Do not kink or pull cable around sharp corners. recommended procedure chart. 2. Keep the gun cable as straight as
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Section C Section C TABLE OF CONTENTS - ACCESSORIES SECTION - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 3/64” (1.2mm) Aluminum Feeding Kit (K1703-1) . . . . . . . . . . . . . . . C-2 K363P Readi-Reel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Dual Cylinder Mounting Kit . . . . . . . . . . .
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C-2 C-2 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 assemblies supplied standard with the POWER MIG 200. 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 trig- Wire Size Drive Roll Kit ger connector, fixed nozzle an
