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For use with machine 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 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

CUL

OPERATOR???S MANUAL

Copyright ?? 2007 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

POWER MIG 215

POWER MIG 215

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer??s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change ??? This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

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 is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- 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.

??? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose ???Quick Links??? and then ???Product Registration???. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

POWER MIG 215

POWER MIG 215

POWER MIG 215

ELECTRIC SHOCK can kill.

??? Only qualified personnel should perform this installation.

??? Only personnel that have read and understood the POWER MIG 215 Operating Manual should install and operate this equip- ment.

??? Machine must be grounded per any national, local or other applic- able electrical codes.

??? The POWER MIG power switch is to be in the OFF position when installing work cable and gun and when connecting other equip- ment.

UNCRATING THE POWER MIG 215

Cut banding and lift off cardboard carton. Cut banding holding the machine to the skid. Remove foam and corrugated packing material. Untape accessories from Gas Bottle Platform. Unscrew the two wood screws (at the Gas Bottle Platform) holding the machine to the skid. 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 smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air pas- sages and cause overheating.

ELECTRIC SHOCK can kill.

??? Do not touch electrically live parts such as output terminals or internal wiring.

??? All input power must be electrically dis- connected before proceeding.

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. Also be sure the planned installation will meet the U.S. National Electrical Code and local code requirements. This welder may be operated from a single phase line or from one phase of a two or three phase line.

2. Models that have multiple input voltages specified on the nameplate (e.g. 208/230) are shipped con- nected for the highest voltage. If the welder is to be operated on lower voltage, it must be reconnected according to the instructions in Figure A.1 for dual voltage machines.

Make certain that the input power is electrically disconnected before removing the screw on the reconnect panel access cover.

------------------------------------------------------------------------

POWER MIG 215

50/60 HZ

CONNECT TO HOT WIRES

OF A THREE-WIRE, SINGLE

PHASE SYSTEM.

POWER MIG 215

POWER MIG 215

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 closed containers.

ARC RAYS can burn eyes and skin.

??? Wear eye, ear and body protec- tion.

Observe all safety information throughout this manual.

POWER MIG 215

WELDING CAPABILITY
The POWER MIG 215 is rated at 215 amps @ 22 volts, at a 30% duty cycle based on a ten minute cycle time. It is capable of higher duty cycles at lower output currents. The tapped transformer design makes it well suited for use with most portable or in-plant gen- erating systems.
RECOMMENDED PROCESSES AND
EQUIPMENT
The POWER MIG 215 is recommended for GMA welding processes using 10 to 44 lb (4.5 to 20 kg) 2" (51 mm) I.D. spools or Readi-Reel?? coils (with option- al adapter) of .025" through .045" (0.6 ??? 1.2 mm) solid steel, .035" (0.9 mm) stainless, 3/64" (1.2 mm) alu- minum and .035 (0.9 mm), .045" (1.2 mm) Outershield??; as well as .035" (0.9 mm) and .045" (1.2 mm) Innershield?? self-shielding electrodes.
The POWER MIG is factory equipped to feed .035" (0.9 mm) electrodes. It also includes a 200A, 60% duty cycle (or 250A, 40% duty cycle) rated, 15 ft. (3.6 m) GMAW gun and cable assembly equipped for these wire sizes. Use of GMAW processes requires a supply of shielding gas.

3

2

1

WIRE DRIVE ROLL

The drive rolls installed with the POWER MIG have two grooves one for .035(0.9mm) wire and the other for .045(1.2mm) wire. Drive roll size is indicated by the stenciling on the exposed side of the drive roll.

WIRE SIZE CONVERSION PARTS

The POWER MIG 215 is rated to feed .025 through

.045" (0.6-1.2 mm) solid or cored electrode sizes.

The drive roll kits and Magnum 250L gun and cable parts are available to feed different sizes and types of electrodes. See Accessories section.

POWER MIG 215

POWER MIG 215

CONNECTOR BLOCK

SOCKET HEAD

CAP SCREW

POWER MIG 215LOOSEN TIGHTEN

The K468 spindle adapter allows the use of 8" diamter small spools.

POWER MIG 215

POWER MIG 215

C-2ACCESSORIESC-2

MAKING A WELD WITH THE SPOOL GUN

ADAPTER KIT AND SPOOL GUN

INSTALLED

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 the built-in feed- er gun.

??? Disables spool gun operation and spool gun gas solenoid valve.

??? Closing feeder gun trigger starts feeder gun welding and makes both electrodes electrically ???HOT???.

2. Setting spool gun selector switch to the Spool Gun Position and pulling SPOOL GUN Trigger.

??? Disables built-in feeder gun operation and machine gas solenoid valve.

??? Enables spool gun operation and spool gun gas solenoid valve.

??? Closing spool gun trigger starts spool gun weld- ing and makes both electrodes electrically ???HOT???.

3. Operation with POWER MIG 215:

??? Turn the POWER MIG-215 input power ON.

??? Adjusting the voltage tap control will increase or decrease your welding voltage.

??? Adjusting the wire speed control on the spool gun will increase or decrease the spool gun wire feed speed. NOTE: Adjusting the wire feed speed control on the Power Mig Panel has no affect on the spool gun??s wire feed speed.

4. Refer to the procedure decal on the Power Mig for initial aluminum settings. Make a test weld to deter- mine the final settings.

5. To return to normal POWER MIG 215 welding, release the spool gun trigger set spool gun selector switch to normal and reset feeder gun voltage pro- cedure setting if necessary.

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. Either the standard .50" (12.7 mm) flush nozzle or other optional flush or recessed (spray arc) nozzle sizes may be used. (See Table D.2 in this section.)
3. If using optional adjustable slip-on nozzles, see Table D.2 in this section.

POWER MIG 215

3. Lay the gun and cable out straight on a flat surface. Loosen the set screw located in the brass connec- tor at the feeder end of the cable and pull the liner out of the cable.

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. the gas diffuser, at this time, should not be installed onto the end of the gun tube.

6. With the gas diffuser still removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in Figure D.1. Remove any burrs from the end of the liner.

POWER MIG 215

POWER MIG 215

Step 2.POSSIBLE CAUSE.

The second column labeled ???POSSIBLE CAUSE??? lists the obvious external possibilities that may contribute to the machine symptom.

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.

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 AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.

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 AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.

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 AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.

POWER MIG 215

1-F

DIAGRAMS WIRING

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. Give the equipment code number.

1-F

POWER MIG 215

NOTES

POWER MIG 215

NOTES

POWER MIG 215

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.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A

ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-

STELLERS. DIE UNFALLVERH??TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

LEIA E COMPREENDA AS INSTRU????ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS

PR??TICAS DE SEGURAN??A DO EMPREGADOR.

??? 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