Instruction/ maintenance manual of the product IM693 Lincoln Electric
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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.
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.
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.
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.
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.
vi vi MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ..............................................
vii vii MASTER T ABLE OF CONTENTS FOR ALL SECTIONS (cont.) Page Maintenance ....................................................................................................Section D Safety Precautions ..............................................
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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An important point after buying a device Lincoln Electric IM693 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric IM693 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric IM693 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric IM693 you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric IM693 will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric IM693, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric IM693.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric IM693. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric IM693 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
