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IM693
June, 2002
™
POWER MIG 200
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
a
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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 are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, 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 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. Us
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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 hos
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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 provo
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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
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vi vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions.................................................................................................A-2 Uncrating the POWER MIG 200..........................................................
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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 ....................................................
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A-1 A-1 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 208/230/50/60 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°
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A-2 A-2 INSTALLATION Read entire installation section before starting INPUT POWER, GROUNDING AND 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
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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 DETAI
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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 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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B-1 B-1 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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B-2 B-2 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 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 ac
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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 c
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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 Applica
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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 a
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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 Wire Size Drive Roll Kit is equipped with the integrated connector, twist-lock trigger connector, fixed nozzle an
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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 g
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D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS CONTACT TIP AND GAS NOZZLE INSTALLATION 1. Choose the correct size contact tip for the elec- WARNING 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 o
