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RETURN TO MAIN MENU
IM828-A
™
POWER MIG
215
February, 2006
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, think before you act
and be careful.
R
C UL
OPERATOR'S MANUAL
Copyright © 2006 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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Summary of Contents for Lincoln Electric pmn
- Page 1 RETURN TO MAIN MENU IM828-A ™ POWER MIG February, 2006 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 ...
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Page 2: California Proposition 65 Warnings
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. -
Page 3: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 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.
- Page 6 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
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Page 7: Table Of Contents
Wire Size Conversion parts ...B-2 Procedure for Changing Drive Roll ...B-3 Wire Reel Loading ...B-3 Mounting of 10 to 30 lbs. Spools ...B-3 To Start the Welder...B-3 Feeding Electrode...B-4 Idle Roll Pressure Setting ...B-4 Wire Drive Configuration ...B-4, B-5 Making a Weld ...B-5 Avoiding Wire Feeding Problems ...B-6... - Page 8 MASTER TABLE OF CONTENTS FOR ALL SECTIONS (cont.) Maintenance ...Section D Safety Precautions ...D-1 General Maintenance ...D-1 Drive Rolls and guide Tubes ...D-1 Contact Tip and Gas Nozzle Installation ...D-1 Gun Tubes and Nozzles ...D-1 Gun Cable Cleaning ...D-1 Liner Removal and Replacement ...D-2 Gun Handle Disassembly ...D-3 Troubleshooting ...Section E How to Use Troubleshooting Guide...E-1...
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Page 9: Installation
TECHNICAL SPECIFICATIONS – POWER MIG 215 Standard Voltage/Phase/Frequency 208/230/1/50/60 Hz Duty Cycle Welding Current Range 30 – 250Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage/ Fuse or Breaker Frequency (Hz) Size (Super Lag) 208/50/60 230/50/60 Wire Speed Height 31.79 in 808 mm OPERATING TEMPERATURE RANGE -4°F to 104°F(-20°C to +40°C) -
Page 10: Safety Precautions
Roll the machine off the skid assembly. LOCATION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front. A location that minimizes the amount of... - Page 11 A green wire in the input cable connects this contact to the frame of the welder. This ensures proper grounding of the welder frame when the welder plug is inserted into a grounded receptacle.
- Page 12 Be sure that the contact tip, liner, and drive rolls all match the size of the wire being used. WARNING Turn the welder power switch off before installing gun and cable. 1. Lay the cable out straight.
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Page 13: Operation
Read entire Operation section before operating the POWER MIG 215. Observe all safety information throughout this manual. OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. -
Page 14: Product Description
PRODUCT DESCRIPTION The POWER MIG™ 215 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 full range wire feed speed control, and 7 output voltage tap selections provides versatility with ease of use and... -
Page 15: Wire Reel Loading
TO START THE WELDER Turn the “Power Switch” switch to “ON”. With the desired voltage and wire speed selected, operate the gun trigger for welder output and to energize the wire feed motor. POWER MIG 215 CAUTION FIGURE B.1... -
Page 16: Feeding Wire Electrode
FEEDING WIRE ELECTRODE WARNING 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 parts are proper for the wire size and type being used. -
Page 17: Making A Weld
5. Loosen the socket head cap screw that holds the connector bar against the gun bushing. Important: Do not attempt to completely remove the socket head cap screw. 6. Remove the outer wire guide, and push the gun bushing out of the wire drive. Because of the pre- cision fit, light tapping may be required to remove the gun bushing. -
Page 18: Avoiding Wire Feeding Problems
The POWER MIG 215 has built-in protective ther- mostats that respond to excessive temperature. They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating tem- perature because of a frequent overload, or high ambient temperature plus overload. -
Page 19: Accessories
DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that are available for the POWER MIG 215.The item in Bold is supplied standard with the POWER MIG 215. Wire Size .023”-.030” (0.6-0.8 mm) .035” (0.9 mm) Solid .045”... -
Page 20: Making A Weld With The Spool Gun Adapter Kit And Spool Gun Installed
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. -
Page 21: Maintenance
GENERAL MAINTENANCE In extremely dusty locations, dirt may clog the air pas- sages causing the welder to run hot. Blow dirt out of the welder with low-pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts. -
Page 22: Liner Removal And Replacement
LINER REMOVAL AND REPLACE- MENT NOTE: Changing the liner for a different wire size requires replacement of the gas diffuser per Table D.1 to properly secure the different liner. TABLE D.1 Replacement Size Stencilled Diameter of Liner Part on End of Electrodes Used Number Liner Bushing... -
Page 23: Gun Handle Disassembly
GUN HANDLE DISASSEMBLY 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) until the collar reaches a stop. -
Page 24: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 25 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. TROUBLESHOOTING POSSIBLE...
- Page 26 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. TROUBLESHOOTING...
- Page 27 Gas does not flow when gun trigger is pulled. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. TROUBLESHOOTING POSSIBLE...
- Page 28 WIRING DIAGRAMS POWER MIG 215...
- Page 29 WIRING DIAGRAMS POWER MIG 215...
- Page 30 DIMENSION PRINT POWER MIG 215...
- Page 31 NOTES POWER MIG 215...
- Page 32 NOTES POWER MIG 215...
- Page 33 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
- Page 34 Keep your head out of fumes. Turn power off before servicing. Use ventilation or exhaust to remove fumes from breathing zone. Los humos fuera de la zona de res- Desconectar el cable de ali- piración. mentación de poder de la máquina Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
- Page 35 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...