Lincoln Electric IM693 manual

PO WER MIG ™ 200 OPERA TOR’S MANUAL IM693 June, 2002 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 MA[...]

FOR ENGINE powered 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. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

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 secousse électrique: a. Les circuits ?[...]

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 keep it handy for quick reference. Pay par[...]

vi vi MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions...................................[...]

vii vii MASTER T ABLE OF CONTENTS FOR ALL SECTIONS (cont.) Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 General Maintenance .........................[...]

A-1 A-1 INST ALLA TION 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 mm 2 ) 230/50/60 60 33 10 (6 mm 2 ) 8 (10 mm 2[...]

A-2 A-2 INST ALLA TION INPUT POWER, GROUNDING AND CONNECTION DIAGRAMS 1. Before starting the installation, check with the local power company if there is any question about whether your power supply is adequate for the volt- age, amperes, phase, and frequency specified on the welder nameplate. Also be sure the planned installation will meet the U.S[...]

A-3 A-3 INST ALLA TION POWER MIG 200 FIGURE A.3 — Receptacle Diagram CONNECT TO A SYSTEM GROUNDING WIRE. SEE THE UNITED STATES NATIONAL ELECTRICAL CODE AND/OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUNDING. CONNECT TO HOT WIRES OF A THREE-WIRE, SINGLE PHASE SYSTEM OR TO ONE PHASE OF A TWO OR THREE PHASE SYSTEM. OUTPUT POLARITY CONNE[...]

GUN AND CABLE INST ALLA TION The Magnum 250L gun and cable provided with the POWER MIG 200 is factory installed with a liner for .035-.045" (0.9-1.2 mm) electrode and an .035" (0.9 mm) contact tip. Be sure that the contact tip, liner, and drive rolls all match the size of the wire being used. Turn the welder power switch off before instal[...]

B-1 B-1 OPERA TION Read entire Operation section before operating the POWER MIG 200. 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 venti[...]

B-2 B-2 OPERA TION 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 f[...]

B-3 B-3 OPERA TION PROCEDURE FOR CHANGING DRIVE 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 back of the machine. Lift the cast idle roll assembly and allow it to sit in an upright position.. 3. Remove the outside wire guide retaining plate by loose[...]

B-4 B-4 OPERA TION 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 gun parts are proper for the wire size and type being used. Refer to Table C.[...]

B-5 B-5 OPERA TION A VOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the 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 dolly wheels or trucks to run over cables. 4 . [...]

C-1 C-1 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. TABLE C.1 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1) This kit helps push feeding aluminum through stan- dard machine feeder and gun. It provides gun and wir[...]

C-2 C-2 ACCESSORIES MAKING A WELD WITH THE SPOOL GUN ADAPTER KIT AND SPOOL GUN INST ALLED 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 spo[...]

D-1 D-1 MAINTENANCE CONT ACT TIP AND GAS NOZZLE INST ALLA TION 1. Choose the correct size contact tip for the elec- trode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser. 2. Screw the appropriate fixed gas nozzle fully onto the diffuser. Either the standard .50" (12.7 mm) flush nozzl[...]

D-2 D-2 MAINTENANCE 4 . Insert a new untrimmed liner into the connector end of the cable. Be sure the liner bushing is sten- cilled appropriately for the wire size bing used. 5 . Fully seat the liner bushing into the connector. tighten the set screw on the brass cable connector. the gas diffuser, at this time, should not be installed onto the end o[...]

D-3 D-3 MAINTENANCE GUN HANDLE DISASSEMBL Y 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) u[...]

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 your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair po[...]

E-2 E-2 TROUBLESHOOTING PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident There is no wire feed or open cir- cuit voltage when the gun trigger is pulled. Input power is applied to POWER MIG 200. Output voltage and wire feed is pre- sent when gun trigger is not pulled (not activated). Machine output is low. Welds are “ cold ” , [...]

E-3 E-3 TROUBLESHOOTING PROBLEMS (SYMPTOMS) 1. Poor arc striking with electrode sticking or blasting off. POSSIBLE AREAS OF MISADJUSTMENT 1. Make sure settings for wire feed speed and voltage are correct for process being used. 2. The gas shielding may be improper for process being used. 3. Check imput line voltage to be with in machines recommende[...]

E-4 E-4 TROUBLESHOOTING PROBLEMS (SYMPTOMS) Gas does not flow when gun trigger is pulled. POSSIBLE AREAS OF MISADJUSTMENT(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 is pulled there may be a restriction in the gas supply line. 3. The gun cable assembly m[...]

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 diagram 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 a replacement. Give the equipment code number.. POW[...]

F-2 F-2 DIMENSION PRINT 3-00F M19231 POWER MIG 200[...]

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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA E[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

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