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SVM167-A
January, 2011
®
POWER MIG 215
For use with machines having Code Numbers:
11070, 11099, 11247
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 you
act and b
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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 Gasoline Engines The Above For Diesel Engines ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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 open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. 7.a. Use only compressed gas cylinders explosion. containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire. Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mate
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iv iv SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales suiv- échauffement et un risque d’inc
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v v 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® 215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Locatio
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A-2 A-2 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-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® 21
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A-4 A-4 INSTALLATION FIGURE A.1 — Dual Voltage Machine Input Connections 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 con- nected 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 qualified polarity for GMA welding. electrician connect a receptacle (Customer Supplied) or cable to the input power
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A-5 A-5 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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A-6 A-6 NOTES POWER MIG® 215 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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Section B Section B TABLE OF CONTENTS - OPERATION SECTION - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Safety Precautions ................................................................................................B-2 Product Description ...............................................................................................B-3 Recommended Processes and Equipment ............................................
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B-2 B-2 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 cloth- ing. 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
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B-3 B-3 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 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 required
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B-4 B-4 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 the 8. Lower the Readi-Reel to depress the retaining spring and adjustable pressure arm down toward the back of align the other inside ca
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B-5 B-5 OPERATION The pressure arm controls the amount of force the drive FEEDING WIRE ELECTRODE rolls exert on the wire. Proper adjustment of both pres- sure arm gives the best welding performance. For best WARNING results, set both pressure arms to the same value. When triggering, the electrode and Set the pressure arm as follows (See Figure B.2a): drive mechanism are electrically “hot” Aluminum wires between 1 and 3 relative to work and ground and Cored wires between 3 and 4 remain “hot” seve
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B-6 B-6 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 bushing o
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B-7 B-7 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 ch
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B-8 B-8 NOTES POWER MIG® 215 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
