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IM828-A
February, 2006
™
POWER MIG 215
For use with machine Code Numbers 11070, 11099, 11247
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, th
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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 PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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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 t
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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 215 INPUT – SINGLE PHASE ONLY Standard Voltage/Phase/Frequency Input Current @ 170 Amp Rated Output Input Current @ 215 Amp Rated Output 208/230/1/50/60 Hz (With 115V receptacle loaded to 15A) (With 115V receptacle loaded to 15A) 39/35 Amps 45/41 Amps RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 30% 215 Amps 22 Volts 40% 190 Amps 23 Volts 60% 170 Amps 24 Volts OUTPUT Welding Current Range Maximum Open Circuit Voltage Welding Vol
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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 WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as ELECTRIC SHOCK can kill. output terminals or internal wiring. • Only qualified personnel should • All input power must be electrically dis- perform this installation. connected before proceeding. • Only personnel that have read and understood the POWER MIG 215
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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 OUTPUT POLARITY CONNECTIONS shipped with a 7 ft.(2.1m). input cable and plug connected to the welder. The welder, as shipped from the factory, is connected for electrode positive (+) polarity. This is the normal 4. Using the instructions in Figure A.2, have a quali- polarity for GMA welding. fied electrician connect a receptacle (Customer Supplied) or cable to the in
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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 215 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 215. 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 cl
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B-2 B-2 OPERATION PRODUCT DESCRIPTION LIMITATIONS The output voltage/current of the POWER MIG 215 is The POWER MIG™ 215 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 PROCEDURE FOR CHANGING when feeding 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 1. Turn off the power source. in the retaining spring tab. 2. Release the pressure on the idle roll by swinging 8. Lower the Readi-Reel to depress the retaining spring and the adjustable pressure arm down toward the back align the other inside cage
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B-4 B-4 OPERATION Set the pressure arm as follows (See Figure B.2a): FEEDING WIRE ELECTRODE Aluminum wires between 1 and 3 Cored wires between 3 and 4 WARNING Steel, Stainless wires between 4 and 6 When triggering, the electrode and drive mechanism 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 CORED W
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B-5 B-5 OPERATION 5. Loosen the socket head cap screw that holds the 3. Press the trigger to feed the wire electrode through connector bar against the gun bushing. the gun and cable. For solid wire cut the electrode Important: Do not attempt to completely within approximately 3/8" (10 mm) of the end of the remove the socket head cap screw. ® contact tip [3/4" (20 mm) for Outershield ]. 6. Remove the outer wire guide, and push the gun 4. When welding with gas, turn on the gas supply and bushin
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B-6 B-6 OPERATION 9. When no more welding is to be done, close valve INPUT LINE VOLTAGE VARIATIONS on gas cylinder (if used), momentarily operate gun High Line Voltage — Higher than rated input voltage trigger to release gas pressure, and turn off will result in output voltages higher than normal for a POWER MIG 215. given tap setting. If your input line is high, you may want to select a lower voltage tap than given on the NOTE: When using Innershield electrode, the gas recommended procedure c
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C-1 C-1 ACCESSORIES DRIVE ROLL KITS ALTERNATIVE MAGNUM GMAW Refer to Table C.1 for various drive roll kits that are GUN AND CABLE ASSEMBLIES available for the POWER MIG 215.The item in Bold is supplied standard with the POWER MIG 215. The following Magnum 250L gun and cable assem- blies are separately available for use with the POWER MIG 215. Each is rated 250 amps 40% 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
