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PO WER MIG ™ 215 OPERA TOR’S MANUAL IM828-A February, 2006 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 Mar. ‘93 POWER MIG 215 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.
v v 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 Read entire installation section before starting installation. SAFETY PRECAUTIONS POWER MIG 215 INPUT POWER, GROUNDING AND CONNECTION DIAGRAMS 1.
3. The 208/230 volt 50/60 Hz model POWER MIG is shipped with a 7 ft.(2.1m). input cable and plug connected to the welder. 4. Using the instructions in Figure A.2, have a quali- fied electrician connect a receptacle (Customer Supplied) or cable to the input power lines and the system ground per the U.
GUN AND CABLE INST ALLA TION The Magnum 250L gun and cable provided with the POWER MIG 215 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 215. 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 ™ 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.
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 mechanism are electrically “ hot ” relative to work and ground and remain “ hot ” several seconds after the gun trigger is released.
B-5 B-5 OPERA TION 3. Press the trigger to feed the wire electrode through the gun and cable. For solid wire cut the electrode within approximately 3/8" (10 mm) of the end of the contact tip [3/4" (20 mm) for Outershield ® ].
B-6 B-6 OPERA TION 9. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off POWER MIG 215. NOTE: When using Innershield electrode, the gas nozzle may be removed from the insulation on the end of the gun and replaced with the gas- less nozzle.
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 215.The item in Bold is supplied standard with the POWER MIG 215. 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.
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 • Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser. • Slip the appropriate gas nozzle onto the nozzle insulator. Either a standard .50" (12.7 mm) or optional .
D-2 D-2 MAINTENANCE 7. Screw the gas diffuser onto the end of the gun tube and securely tighten. Be sure the gas diffuser is correct for the liner being used. (See table and dif- fuser stencil.) 8. Tighten the set screw in the side of the gas diffuser against the cable liner using a 5/64" (2.
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 215 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 215. Output voltage and wire feed is pre- sent when gun trigger is not pulled (not activated).
E-3 E-3 TROUBLESHOOTING PROBLEMS (SYMPTOMS) Poor arc striking with electrode sticking or blasting off. Auxiliary receptacle is “ dead ” - no auxiliary voltage. Rough wire feeding or wire will not feed but drive rolls are turning. POSSIBLE CAUSE 1.
E-4 E-4 TROUBLESHOOTING PROBLEMS (SYMPTOMS) The wire feed stops while welding. When trigger is released and pulled again the wire feed starts. No control of wire feed speed. Other machine functions are nor- mal. Gas does not flow when gun trigger is pulled.
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 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-3 F-3 DIMENSION PRINT 3-00F M19231 POWER MIG 215.
NOTES POWER MIG 215.
NOTES POWER MIG 215.
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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