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Lincoln Electric SVM157-A User's Manual

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1. OTOR CURRE EEDBACK gat x LINCOLN B R103 TOOK NOTE This diagram is for reference only POWER MIG 200 SCHEMATIC CONTROL 3850 1B0 1 It may not be accurate for all machines covered by this manual ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY CONTROL oio O e ITEM REQD PART No DESCRIPTION ITEM REQ D PART No DESCRIPTION el FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECFICATIONS 1 4 E B R16R17 R27 R70 R118 5 525000 12125 RESISTOR SMD METAL FILM 1 10W12 1K 1 02 9 2 R18 R75 2 525000 10006 RESISTOR SMD METAL FIM HOMME FOR ITEMS BELOW REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS 2 R19 R34 R61 R110 R111 R119 R 123 7 __ 525000 15025 RESISTOR SMD METAL FILM 1 10W 15 0K 1 ci 1 813490 179 CAPACITOR ALEL 1000 35V 20 R20 R32 R73 8127 4 s25000 1002SMT RESISTOR SMD METAL FILM 1 10
2. IT 5 8 109A 9 lt 110A H 10 lt 111A 11 WIRE FEED 112A 12 SPEED 13 14 15 lt 16 106 9 2 Return to Section Return to Master TOC MOUNTED RECTIFIER GAS 1 DIODE BRIDGE SOLENOID lt lt 3 4 5 6 JUMPER PLUG INSTALLED FOR NON SPOOL GUN OPERATION SINGLE PHASE BRIDGE RECTIFIER TO SINGLE PHASE SUPPLY LINE CONTACTOR SELECTOR LL SWITCH RECONNECT PANEL jG POWER TRANSFORMER TO GROUND PER NATIONAL ELECTRICAL CODE MOTOR GEARBOX ojo E ES E gt clt 5 FOR SPOOL GUN OPTION C1ANDC2 C1 31 000 MFD E 50V OUTPUT CHOKE 10 10 2000 L11424 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Master TOC LINCOLN B Return to Section TOC Return to Master TOC Return to Section T
3. DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 cc F 37 TROUBLESHOOTING AND REPAIR OUTPUT CAPACITORS REPLACEMENT WARNING 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 or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output capacitors for repair or replacement MATERIALS NEEDED 3 8 Nutdriver 1 2 Wrench This procedure takes approximately 30 minutes to perform POWER MIG 200 LINCOLN F 37 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 5 5
4. E 2 Baffle Mounted Diode Bridge E 2 Control E 3 Output Rectification Contactor amp Control Boards E 3 Optional Circuits E 4 Control Board Gun Trigger amp Wire Drive Motor E 4 Protective Devices amp Circuits E 5 Thermal Overload Protection E 5 Wirefeed Overload Protection E 5 o O 8 FIGURE E 1 THEORY OF OPERATION BLOCK DIAGRAM 2 WIRE GAS SPEED SOLENOID CONTROL WIRE DRIVE MOTOR CONTROL BOARD RECTIFIER DIODE BRIDGE E TRANSFORMER OUTPUT BRIDGE FEEDBACK THERMOSTAT THERMOSTAT GUN TRIGGER LINE SWITCH TAP SELECTOR SWITCH CONTACTOR CONTROL OUTPUT DIODE GUN BRIDGE ASSEMBLY RIDGI OUTPUT POSITIVE CHOKE TERMINAL CONTACTOR CAPACITORS RECONNECT MAIN PANEL TRANSFORMER NEGATIVE TERMINAL o o 0 iv o 4 c tc Return to Master TOC POWER MIG 200 LINCOLN E 2 THEORY OF OPERATION E 2 FIGURE E 2 INPUT POWER CIRCUIT Return to Section TOC Return to Master TOC WIRE SPEED CONTROL GAS SOLENOID CONTROL BOARD TRANSFORMER OUTPUT BRIDGE THERMOSTAT THERMOSTAT FEEDBACK TAP SELECTOR GU
5. 218 5 2 Im Return to Section TOC Return to Master TOC Return to Master TOC 5 THEORY OF PROTECTIVE DEVICES AND CIRCUITS THERMAL AND OVERLOAD PROTECTION The POWER MIG 200 has two built in protective thermostats that respond to excessive temperatures One is located on the main transformer The other thermostat is located on the output rectifier heat sink assembly They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating temperature This can be caused by a frequent overload or high ambient temperature The thermostats are self resetting once the machine cools sufficiently If the thermostat shutdown is caused by excessive output or duty cycle and the fan is operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fan is not turning or the air intake louver are obstructed then the input power must be removed and the fan problem or air obstruction must be corrected OPERATION E 5 WIREFEED OVERLOAD PROTECTION The POWER MIG 200 has solid state overload protection of the wire drive motor If the motor becomes overloaded the protection circuitry turns off the wire feed speed and gas solenoid Check for proper size tip liner drive rolls and any obstructions or bends in the gun cable Check for any other factors that would impede the wire feeding To resume welding simply pull the trigge
6. Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 cc F 19 TROUBLESHOOTING AND REPAIR OUTPUT BRIDGE RECTIFIER TEST WARNING 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 or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if a diode is shorted or leaky See the machine waveform section in this manual for normal and abnormal output wave forms MATERIALS NEEDED Analog Volt ohmmeter or Diode Tester 3 8 Nutdriver 1 2 Nutdriver This procedure takes approximately 20 minutes to perform POWER MIG 200 LINCOLN F 19 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 5 0 218 5 2 Im Return to Section TOC Return to Master TOC F 20 TROUB
7. F 37 5 Main Transformer Replacement F 41 2 Fan Blade Motor F 47 Output Contactor Replacement F 49 2 Retest After F 52 a WARNING ELECTRIC SHOCK can kill Never work on the inside of the machine without removing the input power You can receive a life threatening electrical shock if you fail to do this Only qualified technicians should perform installation maintenance and troubleshooting work on the machine o o 0 iv z o tc Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 cc TROUBLESHOOTING AND REPAIR How To Use Troubleshooting Guide WARNING 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 This Troubleshoot
8. B 6 Welding Thermal Overload Protection B 6 o o 0 iv z o tc Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo OJO Fle 515 0 218 5 2 Im Return to Section TOC Return to Master TOC B 2 OPERATION Read entire Operation section before operating the POWER MIG 200 WARNING 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 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 2 Observe all safety information throughout this manual POWER MIG 200 LINCOLN B 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC Q 2 7 5 B 3 PRODUCT DESCRIPTION
9. 2 7 2 5 cc 1 Disconnect the main input power supply to the machine Q Et 2 c 3 2 Remove the case top and side panels All input power must be electri with a 3 8 nutdriver cally disconnected before pro ceeding RUE 9 Carefully make the following voltage driver tests See Table 4 Locate leads X2 thru X8 located on the output selector switch See Figure 10 Turn Off the machine 11 If any of the voltages are incorrect 5 Locate lead X1 located on the output CNE LOT IDOS Gr rectifier assembly See Figure F2 ine transformer and the test points Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN F 13 POWER MIG 200 LINCOLN 5 ELECTRIC X1 FIGURE F2 LEAD X1 94 7 Wir eL 547 L Ee o UA 4 FIGURE LEAD X9 amp X10 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST continued F 13 DOL Je1Se A 0 uunjeH NOL Je1Se A 0 uunjeu DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes F 14 TROUBLESHOOTING AND REPAIR F 14 TABLE Test Points EXPECTED VOLTAGE READING Return to Section TOC R
10. 5 16 Nut REAR slg ACCESS PANEL 515 a o o 2 ele T x c C C 2 gt 2 C 2 e gt C gt gu gt C gt C gt C A C 2 lt gt 2 Mo A Lead 118 olo OJO Fle 5 5 0 218 5 2 Im 230V 208V L1 L2 FIGURE F 21 REAR ACCESS PANEL CLOSE UP Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN F 46 S T k EE Z E ub DOL Je1Se A 0 Unjo4 NOL Je1Se A 0 DOL J91Se N 01 DOL 181SEIN 0 DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 F 47 TROUBLESHOOTING AND REPAIR FAN BLADE MOTOR REPLACEMENT WARNING 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 or 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 If for any
11. JON ALL ANGLES IS 5 OF DEGREE SUBJECT MATERIAL TOLERANCE 1 TO AGREE ENGINEER UPERSED NG APPROVED SCALE DATE DRAWING 3851 1 NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components not available from Lincoln Electric This information is pro vided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the LINCOLN machine ELECTRIC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 5 0 gt 2 2 EIS Im Return to Section TOC Return to Master TOC SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you If you discover new or different Problems or Symptoms that are not covered in the three col umn troubleshooting chart please share this information with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clai
12. A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo E 515 0 2 2 5 2 Im Return to Section TOC Return to Master TOC Return to Master TOC F 3 TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical con nections To avoid problems when trou bleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistan
13. DIODE SMD 1A 400V FAST RECOVERY DO 21 Z R68 1 825000 37415 RESISTOR SMD METAL FILM 1 10W 3 74K 1 012 1 _ 525040 95 DIODE SMD 3A 200V D0 214AB ULTRA FAST R71 R87 R106 3 525000 10015 RESISTOR SMD METAL FILM 1 10W 1 00K 1 015 018 019 3 525 40 45 DIODE SMD DUAL 0 200A 70V UFR E R74 1 S25000 17825MT RESISTOR SMD METAL FILM 10W 17 8K 1 021 1 52504 25 ZENER DIODE SMD 3W 82V 5 SMB o R76 R100 2__ 25000 8251SMT RESISTOR SMD METAL FILM 1 10W8 25K 1 DZ4 1 525045 15 ZENER_DIODE SMD 225mW 12V 5 SOT 23 O O R77 R78 R89 525000 81905 RESISTOR SMD MET AL FILM 1 10W 6190HMS DZ5 1 525044 15 ZENER DIODE SMD 3W 5 1V 5 SMB Fle R82 R85 2 525001 56215 RESISTOR SMD 5 62K 1 4W 1206 1 TR 026 027 2 25046 1SMT ZENER DIODE SMD 0 5W 5 1V 5 S0D123 E Ix R83 1 525005 15 RESISTOR SMD METAL STRIP 3W 0 050HMS 028 029 2 T1270226 ZENER DIODE 1W 27V 10 1N4750A R84 1 525001 22125 RESISTOR SMD 22 1K 1 4W 1206 1 J 1 524020 16 CONNECTOR MOLEX MINLPCB 16 PIN TIN to R86 1 525000 56225 RESISTOR SMD METAL FILM 1 10W 56 2K 1 2 1 52 020 6 CONNECTOR MOLEX MINI PCB 6 PIN TIN Ola R91 R102 2 525000 20005 RESISTOR SMD METAL FILM 1 10W 2000HMS 1 8240202 CONNECTOR MOLEX MINI PCB 2 PIN TIN R92 R114R117 3 525000 18215 RESISTOR SMD METAL FILM 1 10W 1 82K 1 01 09 2 TRANSISTORSMD 4 10088 R93 R99 2 525000 88115 RESISTOR SMD METAL FILM 1 10W
14. WARNING The liquid electrolyte in contaminated these capacitors is toxic Avoid con tact with any portion of your body The contact tip seizes in the gas dif 1 The tip is being over heated due fuser to excessive current and or high duty cycle A light application of high temper ature anti seize lubricant may be applied to the contact tip threads Return to Section TOC Return to Master TOC Ojo E 515 0 gt 2 2 5 2 1 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 cc F 11 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST WARNING 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 or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock plea
15. check if the problem is resolved Normal potentiometer resistance is 10K ohms 2 Perform the Wire Drive Motor and Tachometer Feedback Test 3 The control board may be faulty Check for adequate wire supply 1 Perform the Wire Drive Motor and Tachometer Feedback Test If the drive rolls are turning check for a mechanical restriction in the 2 The wire speed control potentiometer wire feed path may be faulty Check or replace Normal potentiometer resistance is The gun liner may be clogged 10K ohms Check or replace 3 The control board may be faulty If the drive rolls are not turning when the gun trigger is activated contact your local Lincoln Electric Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo Fle 515 gt g 9 5 2 1 Return to Section Return to Master TOC Return to Master TOC F 9 TROUBLESHOOTING AND REPAIR F 9 Troubleshooting Guide see wiring Diagrams for location of specified Observe Safety Guidelines components and for troubleshooting of specific circuits PROBLEMS POSSIBLE A
16. held together with collar each open For 15 4 5 16087 2 025 030 0 6 0 8 mm 2 up the handle turn the collars approximately 60 shorter Cable M16087 1 035 045 0 9 1 2 mm c degrees counterclockwise the same direction 17714 1 ilum Alm im as removing a right hand thread until the collar reaches a stop Then pull the collar off the gun coNTACT TIPS handle If the collars are difficult to turn position Standard Duty 519391 6 025 0 6 the gun handle against corner place screw S19391 7 030 0 8 mm driver against the tab on the collar and give the ee pd ne 1 to turn the collar past Heavy Buty 319392 1 035 mm 519292 2 045 1 2 mm olo Tapered S19393 5 025 0 6 mm gie 519393 6 030 0 8 S 519393 1 035 0 9 mm it S19393 2 045 1 2 mm Tab For Aluminum 518697 46 3 64 1 2 mm 2 5 Alum Wire Alum Wire EJS GAS NOZZLES 215 Fixed Flush M16081 1 3 8 c M16081 2 1 2 M16081 3 5 8 Recessed M16080 1 3 8 Counterclockwise M16080 2 1 2 PS M16080 3 5 8 Requires Gas Diffuser As bly S19418 3 025 045 Adjustable Slip On M16093 2 1 2 M16093 1 5 8 Requires Nozzle Insulator 819417 1 As bly Requires Gas Diffuser S19418 2 025 030 0 6 0 8 mm As bly S19418 1 035 045 0 9 1 2 mm Ojo Fle 515 0 218 5 2 Im Gasless Nozzle M169
17. 0 218 5 2 Im Return to Section TOC Return to Master TOC F 38 TROUBLESHOOTING AND REPAIR F 38 OUTPUT CAPACITORS REPLACEMENT Continued PROCEDURE 5 1 Using a 3 8 nutdriver remove the lower right side case wraparound cover See Figure F 14 6 2 Locate capacitor bank See Figure F 14 3 Label and remove the five leads connected to the capacitor bank using a 1 2 wrench Note washer position upon removal 8 4 Using a 3 8 nutdriver remove the three capac itor bank nuts and lock washers from the three 9 mounting bolts See Figure F 15 Remove the capacitor bank assembly from the machine Place the new capacitor bank into its proper location inside the machine Replace the three 3 8 nuts and lock washers previously removed Using a 1 2 wrench reconnect the five labeled leads and associated washers previously removed Replace the lower right side case wraparound cover previously removed FIGURE F 14 CAPACITOR BANK LOCATION LOWER RIGHT WRAPAROUND COVER CASE 77 e POWER LINCOLN CAPACITOR BANK ASSEMBLY 200 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 5 0 218 5 2 Im Return to Section TOC Return to Master TOC F 39 TROUBLESHOOTING AND REPAIR F 39 OUTPUT
18. 5 Remove the inside wire guide plate 6 Replace the drive and idle rolls and inside wire guide with a set marked for the new wire size NOTE Be sure that the gun liner and contact tip are also sized to match the selected wire size 7 Manually feed the wire from the wire reel over the drive roll groove and through the wire guide and then into the brass bushing of the gun and cable assembly 8 Replace the outside wire guide retaining plate by tightening the two large knurled screws Reposition the adjustable pressure arm to its original position to apply pressure Adjust pressure as necessary WIRE REEL LOADING READI REELS SPOOLS OR COILS To Mount a 30 Lb 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter Open the Wire Drive Compartment Door 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 3 Place the Optional Adapter on the spindle 4 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining ring groove on the spindle 5 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 6 Position the Readi Reel so that it will rotate in a direction when feed ing so as to be de reeled from top of the coil B 4 OPERATION B 4 7 Set one of the Readi Reel inside cage wires on the slot in the retain ing spring tab 8 Lower the Readi Reel to
19. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source POWER MIG 200 LINCOLN Return to Master TOC Return to Master TOC o o 77 iv o 4 c tc Return to Master TOC SAFETY i 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying
20. Frequency Hz Size Super Lag Nameplate up to 100 ft exceeding 100 ft 208 60 10 6 mm 8 10 mm 230 60 10 6 mm 8 10 mm NOTE Use 10 AWG Grounding Wire PHYSICAL DIMENSIONS Height Depth Weight 31 79 in 38 78 in 210 lbs 808 mm 985 mm 95 kg WIRE SPEED RANGE Wire Speed 50 700 IPM 1 27 17 8 m minute POWER MIG 200 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Ojo O10 E 515 0 gt 2 2 5 2 1 Return to Section Return to Master TOC Return to Master TOC A 3 Read entire installation section before starting installation SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation 0 Only personnel that have read and under stood the POWER MIG 200 Operating Manual should install and operate this equipment Machine must be grounded per any national local or other applicable electri cal codes The POWER MIG power switch is to be in the OFF position when installing work cable and gun and when connecting other equipment UNCRATING THE POWER MIG 200 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 sk
21. K1702 1 Permits stable side by side mounting of two full size 9 dia x 5 high gas cylinders with no lift loading Simple installation and easy instructions provided Includes upper and lower cylinder supports wheel axles and mounting hardware ACCESSORIES 2 ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES The following Magnum 250L gun and cable assemblies are separately available for use with the POWER MIG 200 Each is rated 200 amps 60 duty cycle and is equipped with the integrated connector twist lock trig ger connector fixed nozzle and insulator and includes a liner diffuser and contact tips for the wire sizes spec ified English Wire Metric Wire Length Part No Size Size 10 3 0 m 12 3 6 m 15 4 5 m 10 3 0 m 12 3 6 m 15 45m 035 045 025 030 0 6 0 8 mm TABLE C 2 MAGNUM GUN CONNECTION KIT Optional K466 6 Using the optional K466 6 Magnum Connection kit for the POWER MIG permits use of standard Magnum 200 300 400 gun and cable assemblies SPOOL GUN AND ADAPTER KIT K1809 1 The K1809 1includes the Magnum 25089 Spool gun and the adapter kit for connecting the spool gun to the Power MIG 200 The Adapter Kit provides toggle switch selection between the machine s use with its feeder gun or the spool gun for same polarity welding with different wire and gas processes The kit includes a spool gun adapter module assembly w
22. See the Wiring Diagram 7 lf all wires and connectors are good and the voltage to the drive motor armature is zero the control PC board may be faulty Replace the control PC board 8 If the motor is running at high speed and the armature voltage is high and uncon trollable Proceed with the tachometer test TEST FOR SUPPLY VOLTAGE TO TACHOMETER 1 Disconnect the main AC input power to the machine Do not touch electrically live parts such as output terminals or internal wiring All input power must be electri cally disconnected before pro ceeding a Turn the machine OFF between each test b Carefully insert the meter probes into the lead side of plug J4 FROM LEAD FROM LEAD FROM LEAD 6 If the 5 6 VDC is present check the leads to the tachometer circuit If the leads are okay and 5 6 VDC is pre sent the correct voltage is being received from the control PC board Continue with the supply voltage to tachometer test If the 5 6 VDC is not present and the leads are okay the control PC board may be faulty replace the control PC board Also check plug J5 and the jumper plug See Wiring Diagram POWER MIG 200 LINCOLN F 18 TROUBLESHOOTING AND REPAIR F 18 9g WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued 51 TEST FOR FEEDBACK VOLTAGE the machine ON and pull the 2 2 TO CONTROL BOARD gun trigger to conduct the voltage 212 test 1 Disconnect t
23. The POWER MIGTM 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 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 accuracy Other features include a 2 51 mm O D wire reel spindle with adjustable brake an integral gas cylinder mounting undercarriage an adjustable Argon blend flow regulator with cylinder pressure gauge and inlet hose a 12 ft 3 6 m Magnum 250L GMAW gun and cable with fixed flush nozzle a 7 ft 2 1 m power cable with plug and a 10 ft 3 0 m work cable with clamp Optional Spool Gun and Adapter kit Dual Cylinder Mounting kit and Aluminum Feeding Kit for push feed ing with standard built in feeder are also available RECOMMENDED PROCESSES AND EQUIPMENT The POWER MIG 200 is recommended for GMA weld ing processes using 10 to 44 Ib 4 5 to 20 kg 2 51 mm 1 0 spools or Readi Reel coils with optional 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 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
24. The output Horizontal Sweep capacitor bank was disconnected Each vertical division represents 20 volts and Coupling each horizontal division represents 5 milliseconds in time Trigger Ojo Fle 515 0 218 5 2 Im NOTE Scope probes connected at machine output terminals probe to electrode probe to work Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 cc F 27 TROUBLESHOOTING AND REPAIR CONTROL BOARD REPLACEMENT WARNING 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 or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will
25. birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 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 QUAL IFIED INDIVIDUALS A FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine unt
26. 2 5 cc F 32 TROUBLESHOOTING AND REPAIR F 32 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Continued 1 Place the new wire drive assembly into its 5 proper position 2 Connect plug J4 3 Maneuver assembly back into its original position 4 Replace all mounting screws previously removed POWER MIG LINCOLN Using a 3 4 nut driver replace the thick black lead previously removed Reconnect the gas hose to the wire drive assembly Close case wrap around cover 200 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 cc F 33 TROUBLESHOOTING AND REPAIR OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT WARNING 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 or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you p
27. 3 The output capacitors may be faulty Check for loose connections at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid electrolyte in these capacitors is toxic Avoid con tact with any portion of your body 4 Perform the Output Bridge Rectifier CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER MIG 200 LINCOLN F 10 TROUBLESHOOTING AND REPAIR F 10 Troubleshooting Guide see wiring Diagrams for location of specified Observe Safety Guidelines components and for troubleshooting of specific circuits detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS The weld bead is narrow 1 Make sure the welding proce 1 Perform the Output Bridge Rectifier May have porosity with the elec dures and electrode polarity are Test trode stubbing into the plate correct for the process being used 2 The output capacitors may be faulty Check for loose connections at the Make certain the shielding gas is capacitors Also check for leaky correct and the flow is proper capacitors Replace if necessary Return to Section TOC Return to Master TOC Make sure the weld joint is not
28. 6 81K 1 1 2505 1 4SMT TRANSISTOR SMD NMF SOT 23 0 1 15A 60V e R95 1 s25000 4750SMT RESISTOR SMD METAL FILM 1 10W 4750HMS 08 04 05 06 07 011 013 014 12 525050 15 TRANSISTOR SMD NPN 0 5A 50 23 2 R101 1 525001 15025 RESISTOR SMD 15K 1 4W 1206 1 Q15 016 017 019 c R103 1 525001 10015 RESISTOR SMD 1K 1 4W 1206 1 TR 28 010 012 018 4 25050 2SMT TRANSISTOR SMS PNP SOT23 0 5A 40V MM i R104 R107 2 525001 81915 RESISTOR SMD 6 19K 1 4W 1206 1 TR R1 R55 2 S25000 2801SMT RESISTOR SMD METAL FILM 1 10W 2 80K 1 2 2 R109 1 525056 35 TRIMMER SMD MT 1 4W 50K 10 LINEAR R2 1 525000 31625 RESISTOR SMD METAL OMS BK 4 R112 1 25000 6810SMT RESISTOR SMD METAL FILM 1 10W 681 OHMS R3 R7 R126 3 1 525001 26715 RESISTOR SMD 2 67K 1 4W 1206 195 TR R113 1 525000 22125 RESISTOR SMD METAL FILM 1 10W 22 1K 1 R4 1 _ 525001 24895 RESISTOR SMD 24 90HMS 1 4W 1206 1 TR R125 1 S25000 7500SMT RESISTOR SMD METAL FILM 1 10W 7500HMS R5 R33 R36 R120 4 825000 56215 RESISTOR SMD METAL FILM 1 10W 5 62K 1 128 8129 2 525001 24805 RESISTOR SMD 2490HMS 1 4W 1206 125 TR R6 R26R 121 3 _ 525000 33225 RESISTOR SMD METAL FILM 1 10W 33 2K 1 Ti 1 520375 8 TRANSFORMERPCB PWM FLYBACK R8 1 _ 525001 20015 RESISTOR SMD 2 1 4 1206 1 xi 1 525068 115 IC SMD VOLTAGE REGULATOR STEP DOWN AD R9 R21 R40 R105 4 525001 10005 RESISTOR SMD 1 000HMS 141 1
29. CAPACITORS REPLACEMENT Continued FIGURE F 15 MOUNTING SCREW BOLT LOCATIONS Lead Mounting Bolts 3 8 Nuts amp Lock washers ds 3 places POWER MIG 200 LINCOLN F 40 S T k EE Z E e DOL Je1Se A 0 NOL Je1Se A 0 DOL J91Se N 01 DOL J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 cc F 41 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT WARNING 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 or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The followi
30. It also includes a 200A 60 duty cycle or 250A 40 duty cycle rated 12 ft 3 6 m GMAW gun and cable assembly equipped for these wire sizes Use of GMAW processes requires a supply of shielding gas WELDING CAPABILITY The POWER MIG 200 is rated at 200 amps 9 22 volts at a 3096 duty cycle based on a ten minute cycle time It is capable of higher duty cycles at lower output cur rents The tapped transformer design makes it well suited for use with most portable or in plant generating systems OPERATION B 3 LIMITATIONS The output voltage current of the POWER MIG 200 is subject to vary if the input power to the machine varies due to its tapped transformer power topology In some cases an adjustment of WFS preset and or voltage tap selection may be required to accommodate a signifi cant drift in input power DESCRIPTION OF CONTROLS Power ON OFF Switch Place the lever in the ON position to energize the POWER MIG 200 See Figure B 1 Voltage Control Seven voltage tap selections are provided Labeled A minimum voltage through G maximum voltage It should only be adjusted when not welding The control selection can be preset to the setting specified on the Procedure Decal on the inside of the wire compartment door See Figure B Wire Speed Control This controls the wire feed speed from 50 700 inches per minute 1 2 17 8 m min Wire speed is not affected when changes are made in the voltage
31. Table D 1 to properly secure the different liner MAINTENANCE D 3 4 Insert a new untrimmed liner into the connector end of the cable Be sure the liner bushing is stencilled appropriately for the wire size bing used 5 Fully seat the liner bushing into the connector tight en 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 7 Screw the gas diffuser onto the end of the gun tube and securely tighten Be sure the gas diffuser is cor rect for the liner being used See table and diffuser stencil TABLE D 1 Liner Part Number M16087 2 Diameter of Electrodes Used 025 030 Steel 0 6 0 8 mm Fixed Nozzle Adjustable Nozzle Replacement Size Stencilled Gas Diffuser Gas Diffuser on End of Liner Bushing and Stencil and Stencil 030 0 8 mm Part No Part No S19418 3 S19418 2 035 045 Steel 0 9 1 2 mm M16087 1 045 1 2 mm S19418 3 S19418 1 3 64 Aluminum M17714 1 1 2 mm LINER REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM 250L NOTE The variation in cable lengths prevents the interchangeability of liners between guns Once a liner has been cut for a particular gun it sh
32. This is the normal E E THE UNITED STATES polarity for GMA welding E NATIONAL ELECTRICAL gc E If negative polarity is required interchange the con DETAILS AND MEANS FOR nection of the two cables located in the wire drive com PROPER GROUNDING partment near the front panel The electrode cable CONNECT TO HOT WIRES which is attached to the wire drive is to be connected FUSE THREE WIRE SINGLE to the negative labeled terminal and the work lead PHASE SYSTEM OR TOONE which is attached to the work clamp is to be connect PHASE OF A TWO OR h P label inal THREE PHASE SYSTEM ed to the positive labeled terminal Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Ojo Fle 515 gt 218 5 2 Im Return to Section TOC Return to Master TOC Return to Master TOC A 6 GUN AND CABLE INSTALLATION 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 WARNING Turn the welder power switch off before installing gun and cable 1 Lay the cable out straight 2 Unscrew knurled screw on the drive unit front end inside wire feed compartme
33. aid the technician in removing the control board for replacement MATERIALS NEEDED 5 16 Nutdriver This procedure takes approximately 20 minutes to perform POWER MIG 200 LINCOLN F 27 F 28 TROUBLESHOOTING AND REPAIR F 28 9 9 CONTROL BOARD REPLACEMENT continued Fle Els PROCEDURE 8 1 Remove power to the machine 6 Carefully remove the control board 9 2 2 Using a 5 16 nutdriver remove the three 7 Mount the new board to the nylon mounting 2 2 screws securing the tool tray pins amp 3 Locate control board 8 Reconnect any plugs or leads previously removed 4 Disconnect all associated plugs and leads connected to the control board 9 Replace the tool tray previously removed 5 Depress the retaining pins on the sides of the four nylon mounts to release the control board See Figure F 8 FIGURE F 8 CONTROL BOARD MOUNTING PINS Return to Section TOC Return to Master TOC DEPRESS LOCKING TAB ON MOUNTING PIN Ojo Fle 515 0 218 5 2 Im Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 cc F 29 TROUBLESHOOTING AND REPAIR WIRE DRIVE
34. and type being used FAN CONTROL The fan is designed to come on when input power is applied to the POWER MIG 200 and go off when power is removed B 6 OPERATION B 6 INPUT LINE VOLTAGE VARIATIONS High Line Voltage Higher than rated input voltage will result in output voltages higher than normal for a given tap setting If your input line is high you may want to select a lower voltage tap than given on the recommended procedure chart Low Line Voltage You may not be able to get max imum output from the machine if the line voltage is less than rated input The unit will continue to weld but the output may be less than normal for a given tap setting If your input line is low you may want to select a high er voltage tap than given on the recommended proce dure chart WIRE FEED OVERLOAD PROTECTION The POWER MIG has solid state overload protection of the wire drive motor If the motor becomes over loaded the protection circuitry turns off the wire feed speed and gas solenoid Check for proper size tip liner and drive rolls for any obstructions or bends in the gun cable and any other factors that would impede the wire feeding to resume welding simply pull the trigger There is no circuit breaker to reset as the pro tection is done with reliable solid state electronics WELDING THERMAL OVERLOAD PROTECTION The POWER MIG 200 has built in protective ther mostats that respond to excessive temperature The
35. assistance before you proceed Call 1 800 833 9353 POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo O10 Fle 515 zio gt g 9 5 2 1 Return to Section Return to Master TOC Return to Master TOC F 8 TROUBLESHOOTING AND REPAIR F 8 Troubleshooting Guide see Wiring Diagrams for location of specified Observe Safety Guidelines components and for troubleshooting of specific circuits detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Rough wire feeding or the wire will 1 not feed but the drive rolls are turn ing WIRE FEEDING PROBLEMS The gun cable may be kinked or twisted Check the drive roll tension and the position of the grooves Electrode may be rusted or dirty The contact tip may be damaged or not the correct size Check the wire spindle for ease of rotation Make certain the gun is pushed all No control of wire feed speed Other machine functions are mal There is no wire feed when the gun trigger is activated Normal open circuit weld voltage is present and the gas solenoid functions normally the way into the gun mount and properly seated The wire feed speed control may 1 The wire speed control potentiometer be dirty Rotate several times be faulty Check or replace
36. control See Figure B 1 Figure B 1 Control Locations WIRE FEED SPEED VOLTAGE ON OFF SWITCH WIRE DRIVE ROLL The drive rolls installed with the POWER MIG each have two grooves both for 030 035 0 8 0 9 mm solid steel electrode Drive roll size is indicated by the stenciling on the exposed side of the drive roll If feed ing problems occur then the drive roll may be reversed or changed See Rollin this section WIRE SIZE CONVERSION PARTS The POWER MIG 200 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 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC Q 9 5 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 3 Remove the outside wire guide retaining plate by loosening the two large knurled screws 4 Wiggle both the metal idle and drive rolls off of their plastic hubs
37. de la masse Un court circuit accidental peut provoquer un chauffe ment et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les gal vanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres pro duits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou
38. detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output contactor for repair or replacement MATERIALS NEEDED 7 16 Wrench 5 16 Nutdriver This procedure takes approximately 40 minutes to perform POWER MIG 200 LINCOLN F 49 F 50 TROUBLESHOOTING AND REPAIR F 50 OUTPUT CONTACTOR REPLACEMENT Continued PROCEDURE 7 Replace output contactor 1 Using a 5 16 nutdriver remove the three screws securing the tool tray 8 Using a 7 16 wrench mount the new output contactor in its proper location 2 Locate the output contactor See Figure F 23 Return to Section TOC Return to Master TOC 9 Reconnect leads 106B 106C amp 107A to their proper terminals See Wiring Diagram 3 Using a 7 16 wrench label and remove the two thick black leads at the top of the output contactor Note lead and washer placement for reassembly 10 Reconnect the two thick black leads previ ously removed from the top of the output contactor 11 Replace the tool tray using a 5 16 nutdriv 4 Remove lead 107A and note lead place B ment See Figure F 23 5 Remove leads 106B and 106C See Figure F 23 6 Usi
39. la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place POWER MIG 200 LINCOLN RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety sante Ph a i iv Installation il eee 525254154 cos Section A 222585 rp rM Section B Accessories Section C Maintenance cl RR RII Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual P372 amp P202 H 2 POWER MIG 200 LINCOLN Section A TABLE OF CONTENTS Section A INSTALLATION SECTION o Section A Technical Specifications A 2 Safety Precautions A 3 Unerating the Power 200 d Locatio
40. reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the fan blade and fan motor for repair or replacement MATERIALS NEEDED 3 8 Nutdriver 5 16 Nutdriver 11 32 Open End Wrench Flathead Screwdriver This procedure takes approximately 45 minutes to perform POWER MIG 200 LINCOLN F 47 F 48 TROUBLESHOOTING AND REPAIR F 48 FAN BLADE MOTOR REPLACEMENT Continued PROCEDURE 8 Replace the fan motor and fan blade if nec 1 Using a 3 8 nutdriver remove the lower essary right side of the case wraparound cover Return to Section TOC Return to Master TOC 2 Perform the Output Capacitor Bank 9 Tighten the fan blade mounting band Removal Procedure 10 Carefully manuver the fan assembly into its 3 Using a 5 16 nutdriver remove the four fan original position mounting screws from the rear of the machine See Figure F 22 11 Replace the two 11 32 fan motor mounting nuts and lockwashers 4 Using an open end 11 32 wrench remove the two fan motor mounting nuts and lock washers See Figure F 22 12 Replace the four 5 16 fan assembly mount ing screws in the rear of the machine NOTE Make sure the fan blade is free to rotate when all o
41. should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 POWER MIG 200 LINCOLN Return to
42. terminals is low when the 12 VDC is applied the contactor is good F 22 low the contacts are stuck and y CAUTION the contactor is faulty Replace Do not leave the 12 VDC applied to the When the test is complete replace contactor coil for a prolonged period of leads 106B 106C and 107A time 15 seconds maximum Damage to contactor may result 3 S lead from the contactors large terminals H ela NOTE When the contactor is activated T 9 the resistance between the 5 Carefully apply 12 VDC 10 the contactor terminals should be very high elg coil leads small terminals infinite If the resistance is always cle 2 2 11 Replace the lead previously removed from one of the contactor large 6 If the contactor does not activate when terminals the 12VDC is applied the contactor is taulty Raplaca 12 Replace the tool tray Figure F 7 Contactor Terminals and Leads Ojo Fle 515 0 218 5 2 Im Output Contactor Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo Fle 515 0 218 5 2 Im Return to Section TOC Return to Master TOC F 23 TROUBLESHOOTING AND REPAIR F 23 TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE
43. the GMAW process to be used Typically the con tact tip end should be flush to 12 3 2 mm extended for the short circuiting transfer process and 12 3 2 mm recessed for spray transfer GUN TUBES AND NOZZLES 1 Replace worn contact tips as required 2 Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required GUN CABLE CLEANING To help prevent feeding problems clean cable liner after using approximately 300 pounds 136 kg of elec trode Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using an air hose and only partial pressure gently blow out the cable liner from the gas diffuser end POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo O10 E 515 0 2 2 5 2 Im Return to Section TOC Return to Master TOC Return to Master TOC D 3 CAUTION Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out If this has been done and feed problems are experienced try liner replacement and refer to the trouble shooting section on rough wire feeding LINER REMOVAL AND REPLACE MENT NOTE Changing the liner for a different wire size requires replacement of the gas diffuser per
44. the outer wire guide plate installed Manually feed the wire through the incoming guide bushing and through the guide plates over the drive roll groove Push a suf ficient wire length to assure that the wire has fed into the gun and cable assembly without restriction Reposition the adjustable pressure arm to its origi nal position to apply pressure to the wire 4 Press gun trigger to feed the electrode wire through the gun IDLE ROLL PRESSURE SETTING The optimum idle roll pressure varies with type of wire wire diameter surface conditions lubrication and hardness As a general rule hard wires may require greater pressure and soft or aluminum wire may require less pressure than the factory setting The opti mum idle roll setting can be determined as follows 1 Press end of gun against a solid object that is elec trically isolated from the welder output and press the gun trigger for several seconds 2 If the wire birdnests jams or breaks at the drive roll the idle roll pressure is too great Back the adjustment knob out 1 2 turn run new wire through gun and repeat above steps 3 If the only result was drive roll slippage loosen the adjustment knob on the conductor plate and pull the gun cable forward about 6 15 cm There should be a slight waviness in the expose wire If there is not waviness the pressure is too low Tighten the adjustment knob 1 4 turn reinstall the gun cable and repeat the above steps O
45. triggering circuit plugs may be faulty See the wiring diagram 5 The control board may be faulty Ojo Fle 515 0 gt g 9 5 2 1 CAUTION If for any reason you do understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC F 5 TROUBLESHOOTING AND REPAIR F 5 Troubleshooting Guide see wiring Diagrams for location of specified Observe Safety Guidelines components and for troubleshooting of specific circuits detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Continued continued from previous page Check the gun trigger leads Leads 324 to 325 should have continuity zero ohms when the gun trigger is activat ed f not the gun trigger or cable may be faulty Check or replace Return to Section TOC Return to Master TOC spool gum option kit is installed check to make sure it is set to the normal position if using the POWER MIG 200 built in wire feeder When the gun trigger is activated 1 Make sure the gun cable and 1 Check the output selector and the wire feeds normally but work cables are connected switch for proper oper
46. which require no service DRIVE ROLLS AND GUIDE PLATES After every coil of wire inspect the wire drive mecha nism Clean it as necessary by blowing with low pres sure compressed air Do not use solvents for cleaning the idle roll because it may wash the lubricant out of the bearing drive rolls are stamped with the wire sizes they will feed If a wire size other than that stamped on the roll is used the drive roll must be changed For instructions on replacing or changing drive roll see Wire Drive Rolls in Operation section MAINTENANCE D 2 CONTACT TIP AND GAS NOZZLE ein Choose the correct size contact tip for the electrode 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 n this section 3 If using optional adjustable slip on nozzles see Table D 2 in this section Besurethe 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 62 15 9 mm I D slip on gas nozzle may be used and should be selected based on the welding application Adjust the gas nozzle as appropriate for
47. work distance is about 3 8 10 mm 3 4 20 mm for Outershield 9 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out 10 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 200 POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures Do not kink or pull cable around sharp corners Keep the gun cable as straight as possible when welding or loading electrode through cable 3 Do not allow dolly wheels or trucks to run over cables 4 Keep cable clean by following maintenance instruc tions 5 Use only clean rust free electrode The Lincoln electrodes have proper surface lubrication 6 Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed 7 Keep wire reel spindle brake tension to minimum required to prevent excess reel over travel which may cause wire loop offs from coil 8 Use proper drive rolls and wire drive idle roll pres sure for wire size
48. 00 51115 RESISTOR SMD MET AL FILM 1 10W5 11K 1 13 16 2__ 525020 145 CAPACITOR SMD CERAMIC 330pF 100 556 3 30 V R48 R49 2 525004 24305 RESISTOR SMD 1W 2430HMS 1 C20 C21 2 525024 105 CAPACITOR SMD TANT ALUM 22MF 25V 10 S 5 385 1 1 C21 C20 a CONT R52 1 _ 525000 47515 RESISTOR SMD METAL FILM 1 10W4 75K 1 C25 C26 2 825020 75 CAPACITOR SMD CERAMIC 0 22MF 50V 20 3 10 ce d IT 1 R53 R108 2 525000 39225 RESISTOR SMD METAL FILM 1 10W 39 2K 1 C33 1 525020 65 CAPACITOR SMD CERAMIC 4700pF 50V 5 6 C d JL R54 1 525056 25 TRIMMER SMD MT 1 4W 2K 10 LINEAR C45 1 525024 65 CAPACITOR SMD TANTALUM 22MF 16 10 5 t R56 1 S25001 12128MT RESISTOR SMD 12 1K 1 4W 1206 1 C46 1 525024 85 CAPACITOR SMD TANTALUM 10MF 16V 10 S 865 7 ar R58 R81 2 525001 26725 RESISTOR SMD 26 7K 1 4W 1206 1 TR C49 1 525024 35 CAPACITOR SMD TANT ALUM 2 2MF 20V 10 R59 1 525000 90915 RESISTOR SMD METAL FILM 1 10W 9 09K 1 D1 02D3D4D5D16 6 525040 115 DIODE SMD 1A 600V S403A ULTRA FAST RE 8 e R60 1 525000 24315 RESISTOR SMD METAL FILM 1 10W2 49K 1 D6 D9D10D14D17 5 S25049 45MT DIODE SMD DUAL 200MA 30V SCHOTTKY SOT amp Lm LI R62 1 S25000 33205MT RESISTOR SMD METAL FILM 1 10W 3320HMS D7 1 _ 525049 25 DIODE SMD 1A 30V SMA SCHOTTKY EX 226 GE R66 1 __ 525000 24325 RESISTOR SMD METAL FILM 1 10W 24 3K 1 D8 D11 D13 3 _ 525040 15
49. 206 1 x2 1 523060 15 IC SMD SWTCH LO SIDE 2 2A 60V SOT 22 R10 1 s25001 5R0SMT RESISTOR SMD 15 00HMS 1 4W 1206 1 TR X3 X9 2 515128 115 IC SMT COMPARATOR QUAD 29010 R11 R72 R94 3 _ 525000 16525 RESISTOR SMD METAL FILM 1 10W 16 5K 1 x 1 525067 15 IC BIPOLAR TIMER SOIC 14 R12 1 825000 68125 RESISTOR SMD METAL FILM 1 10W 68 1K 1 x 1 _ 525068 25 IC SMT CMOS DRIVER MOSFET 2113 55 R13 R25 RAS ROB 4 825000 33215 RESISTOR SMD METAL FILM 1 10W 3 32K 1 X6 1 St5128 185MT IC OP AMP SMT QUAD HIGH PERF 330740 R14 R24 R57 3 525001 10045 RESISTOR SMD 1 00M 1 4W 1206 1 TR X 1 13552 25 IC CONVERTER FN 2907 50 8 R15 R65 2 _ 525000 47535 RESISTOR SMD METAL FILM 1 1 0W 475K 1 x 1 815128 45 OP AMP SMD QUAD GEN PURPOSE 224D ALES OTH RWISESPECIHED CAPACITANCE MFD VOLTS INDUCTANCE HENRIES RESISTANCE OHMS 0 20 5 60 5 80 O o E 5 5 Oo PEN 9 gt 212 5 5 5 91 o o olo HS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION CF THEUNCOLN ELECTRIC COMPANY CLEVELAND OHOUS A MANUFACTURNGIOLERANCE PERE2056 _ Sheet No DESIGNINFORMATION QREFERENCE EQUIPMENT TYPE ON 2 PLACE DECIMALS IS 02 XA 10 20 2000 ON 3 PLACE DECIMALS I 002 DRAWN BY 111101
50. 38 For Innershield GUN TUBE ASSEMBLIES Standard 60 818920 45 519890 Included with POWER 200 Requires S19418 1 Gas Diffuser Assembly Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN D 5 Lu 9 s c UE E t c 5 gt gt gt gt 2 Q E gt E 6 o O a o o Q o 2 2 E a 6 lt gt a o x o 5 2 o 4 3 5 585 9 9 mat ale 9 4 NOL Je1Se A 0 DOL 4 0 DOL J91Se N 01 DOL J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes D 6 S T k EE Z E a DOL Je1Se A 0 NOL Je1Se A 0 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Section E TABLE OF CONTENTS Section E THEORY OF OPERATION SECTION o O 5 o E Theory of Operation Section E Input Power Circuit E 2 Input Line Voltage E 2 5 Main Transformer E 2 d Voltage Selector Switch
51. LESHOOTING AND REPAIR OUTPUT BRIDGE RECTIFIER TEST continued TEST PROCEDURE 1 Remove input power to the POWER MIG 200 machine Using the 3 8 nutdriver remove the left case side Locate and disconnect the negative lead from the output rectifier bridge assembly Be sure there is no electrical contact between the rectifier and the lead See Figure F 6 NOTE Do not disassemble the rectifier assembly 4 Test for shorted or leaky diodes by checking from the anodes to the cathodes of the diode heatsink plates The readings should be high resistance in one polarity and low resistance in the opposite polarity If any of the diodes are leaky or shorted the output rectifier assembly should be replaced When the test is complete replace the negative output lead previously removed 7 Replace the left case side Figure F 6 Rectifier Test Points Negative Lead POWER MIG 200 LINCOLN F 20 F 21 TROUBLESHOOTING AND REPAIR F 21 CONTACTOR TEST WARNING 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 or 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 Return to Section TOC Return to Mast
52. LOADED G _ LL LL lll __ L tt tet ptt tt 10 0 V 5 ms MACHINE LOADED 200 5 AT 22 VDC SCOPE SETTINGS This is a typical DC output voltage wave form generated from a properly operat Volts Div ing machine Note that each vertical division represents 10 volts and that Horizontal Sweep each horizontal division represents 5 milliseconds in time The machine was Coupling loaded with a resistance grid bank Trigger NOTE Scope probes connected at machine output terminals probe to electrode probe to work POWER MIG 200 LINCOLN F 24 TROUBLESHOOTING AND REPAIR F 24 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM G Q Volts _ Return to Section Return to Master TOC Return to Section TOC Return to Master TOC SCOPE SETTINGS This is a typical DC output voltage wave form generated from a properly operat Volts Div 20V Div ing machine Note that each vertical division represents 20 volts and that Horizontal Sweep 1 0 ms Div each horizontal division represents 1 0 milliseconds in time Coupling Ojo Fle 515 0 218 5 2 Im NOTE Scope probes connected Trigger machine output terminals probe to electrode probe to work Return to Section TOC Return
53. MOTOR ASSEMBLY REPLACEMENT WARNING 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 or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the wire drive and tachometer for repair or replacement MATERIALS NEEDED 5 16 Nutdriver 9 16 Nutdriver Pliers Small Flathead Screwdriver This procedure takes approximately 50 minutes to perform POWER MIG 200 LINCOLN F 29 F 30 TROUBLESHOOTING AND REPAIR F 30 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Continued FIGURE 9 WIRE DRIVE LOCATION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Wire Drive PROCEDURE 5 Using a 5 16 nutdriver remove the three mounting screws next to the wire drive assembly See Figure 10 6 Using a 5 16 nutdriver remove the two screws on the case front assembly 3 Using a pair of pliers disconnect the ga
54. Master TOC Return to Master TOC o 2 7 2 z Return to Master SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout con tact entre les parties sous tension et la peau nue ou les v te ments mouill s Porter des gants secs et sans trous pour isol er les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans le s positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir e Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la ten sion vide des deux machines f Si
55. N TRIGGER SWITCH CONTACTOR CONTROL GUN ASSEMBLY OUTPUT POSITIVE CHOKE TERMINAL CONTACTOR OUTPUT CAPACITORS NEGATIVE RECONNECT PANEL TERMINAL MAIN TRANSFORMER Return to Section TOC Return to Master TOC 515 0 5 2 Im Return to Section TOC Return to Master TOC INPUT LINE VOLTAGE MAIN TRANSFORMER VOLTAGE SELECTOR SWITCH AND BAFFLE MOUNTED DIODE BRIDGE The single phase input power is connected to the POWER MIG 200 through a line switch located on the front panel reconnect panel allows the user to configure the machine for the desired input voltage The AC input voltage is applied to the primary of the main transformer The cooling fan motor 120 is powered from a portion of the primary winding For welding purposes the main transformer converts the high voltage low current input power to a lower voltage higher current output This tapped secondary winding is coupled to a voltage selector switch By selecting one of seven positions on the switch the user can preset the desired voltage output from a minimum setting A to a maximum voltage setting G In addition the main transformer houses a 28VAC winding This 28VAC is rectified at the baffle mounted diode bridge and the resultant DC voltage is used to power the electronics on the control board the output contactor and the gas so
56. Nozzles D 2 Gun Cable Cleaning D 2 Liner Removal and Replacement D 3 Gun Handle Disassembly D 4 Accessories and replacement parts for Magnum 250L Gun amp Cable Assemblies D 4 Major Component Location D 5 Return to Master TOC o o 0 iv z o tc Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 2 Return to Section Return to Master TOC 9 2 5 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill T e Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts READ THE SAFETY PRECAUTIONS IN THE FRONT OF THIS MANUAL BEFORE WORKING ON THIS MACHINE 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 The fan motors have sealed ball bearings
57. OC Return to Master TOC O o Fle 5 5 Oo PEN 2 8 cic 5 2 1 Return to Section Return to Master TOC G 3 ELECTRICAL DIAGRAMS SCHEMATIC CONTROL PC BOARD TRIGGER 30 0022 50V m i MAIN MOT CONTRO THRESH 11 CNTVOL arsch BP 8 TRIG OUT RESET 5550 RESET gt SHT2 RELEASE SPOOL GUN KIT AMPHENOL PINS AVERAGE CURRENT SHUTDOWN GER DISABLE 5 RIGGER_UISABL gt sur 2 SPOOL GUN MOTO DUTY CYCLE SETPO EAK CURR gt BRAKE ON DRIVE SIGNAL G
58. PERATION B 5 MAKING A WELD 1 Check that the electrode polarity is correct for the process being used then turn the power switch ON 2 Set desired arc voltage tap and wire speed for the particular electrode wire material type and thick ness and gas for GMAW being used Use the Application Chart on the door inside the wire com partment as a quick reference for some common welding procedures 3 Press the trigger to feed the wire electrode through the gun and cable and then cut the electrode within approximately 3 8 10 mm of the end of the con tact tip 3 4 20 mm Outershield 4 f welding gas is to be used turn on the gas supply and set the required flow rate typically 25 35 CFH 12 16 liters min 5 When using Innershield electrode the gas nozzle may be removed from the insulation on the end of the gun and replaced with the gasless nozzle This will give improved visibility and eliminate the possi bility of the gas nozzle overheating 6 Connect work cable to metal to be welded Work clamp must make good electrical contact to the work The work must also be grounded as stated in Arc Welding Safety Precautions WARNING When using open arc process it is necessary to use correct eye head and body protection 7 Position electrode over joint End of electrode may be lightly touching the work 8 Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to
59. POWER MIG 200 For use with machines having Code Numbers 10564 10584 Return to Master TOC View Safety Info 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 be careful Return to Master TOC View Safety Info 915 21 gjo al SERVICE MANUAL View Safety Info LI NCOLN Copyright 2001 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 Return to Master TOC Return to Master TOC Return to Master TOC o o 77 iv o 4 c tc Return to Master TOC SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm The engine exhaust from this product contains chem icals known to the State of California to cause cancer
60. REAS OF SYMPTOMS MISADJUSTMENT S Poor arc striking with electrode 1 sticking or blasting off WELDING PROBLEMS Make sure the settings for wire feed speed and voltage are cor rect for the process being used Make certain the gas shielding is correct for the process being used Make sure the machine s recon The arc is unstable and or hunting nect panel is configured properly for the input voltage being applied Check for a worn or melted con tact tip Check for loose or faulty connec tions on the work and gun cables Make sure the electrode polarity is correct for the welding process being used Check for rusted or dirty electrode wire Make sure the machine s settings and shielding gas are correct for the process being used detailed in the beginning of this manual RECOMMENDED COURSE OF ACTION 1 The output capacitors may be faulty Check for loose connections at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid electrolyte in these capacitors is toxic Avoid con tact with any portion of your body 2 Perform the Output Diode Rectifier 1 Check for loose or faulty connections at the output terminals choke output capacitors output selector switch output contactor and all heavy cur rent carrying leads See the wiring diagram 2 Check the output selector switch for proper operation and good connec tions
61. S COURSE OF ACTION PROBLEMS SYMPTOMS Output voltage and wire feed speed is present when the gun trigger is NOT activated The machines output is low Welds are cold The weld beads are rounded or humped demonstrat ing poor wetting into the plate The machine cannot obtain full rated output of 200 amps at 22VDC when the gun trigger is NOT activat ed The wire feed functions normal ly OUTPUT PROBLEMS Continued Remove the gun assembly the problem is resolved the gun assembly is faulty Repair or replace If the problem is NOT resolved the fault is within the POWER MIG 200 machine Check the input voltage Make sure the machine is configured properly for the input voltage being applied Make sure the settings for wire feed speed and voltage are cor rect for the process being used Make sure the electrode polarity is correct for the process being used Check the welding cables and gun for loose or faulty connec tions stuck closed F 6 Observe Safety Guidelines detailed in the beginning of this manual 1 Check for shorts in the trigger circuitry within the POWER MIG 200 machine See the wiring diagram The control board may be faulty Check for loose or faulty con nections on the heavy current carrying leads inside the POWER MIG 200 See the Wiring Diagram 2 The output capacitors may be faulty Check for loose connec tions at the capacitors Al
62. See Technical Specifications at the beginning of this chapter for proper wire sizes For long runs over 100 feet larger copper wires should be used Fuse the two hot lines with super lag type fuses as shown in the following diagram The center contact in the receptacle is for the grounding connection 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 insert ed into a grounded receptacle POWER MIG 200 LINCOLN amp 5 INSTALLATION 5 FIGURE 2 Triple Voltage Machine Input Connections INPUT SUPPLY CONNECTION DIAGRAM Return to Section TOC Return to Master TOC Disconnect input power before inspecting or servicing machine Do operate with covers removed ELECTRIC SHOCK CAN KILL Only qualified persons should install use or service this equipment Do not touch electrically live parts Install and Ground machine National Electrical Code and local codes Use Grounding Stud Lug inside Use CU wire only Consult Instruction Manual before installing or operating o HE Q o 2 5 2 Return to Master 524373 9 5 5 OUTPUT POLARITY CONNECTIONS 9 FIGURE A 3 Receptacle Diagram o 12 The welder as shipped from the factory is connected 8 2 SES for electrode positive polarity
63. See Wiring Diagram removed 1 Using 5 16 nutdriver replace the tool tray 4 Using a 5 16 nutdriver close the rear access panel previously opened 1 Using a 3 8 nutdriver replace both sides of the case wraparound cover Return to Section TOC Return to Master TOC FIGURE 17 LEADS X9 X10 104B 104C amp H1B Fle 5 0 218 5 2 Im A x10 Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC E 5 5 0 2 2 5 2 Im Return to Section TOC Return to Master TOC F 44 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT Continued FIGURE F 18 LEADS SWITCH LEADS X2 X5 X6 a rc FIGURE F 19 LEAD 121 amp 118 POWER MIG 200 LINCOLN F 44 F 45 TROUBLESHOOTING AND REPAIR F 45 9 MAIN TRANSFORMER REPLACEMENT Continued FIGURE 20 ACCESS PANEL b o 2 elec 2 2 INPUT
64. W 10 0K 1 C2 1 525020 55 CAPACITOR SMD CERAMIC 2700pF 50 5 o R22 1 525000 61915 RESISTOR SMD METAL FILM 1 10W 6 19K 1 ca 1 513490 182 CAP ALEL 3300 63V 20 R23 1 525000 22115 RESISTOR SMD METAL FILM 1 10W2 21K 1 c4 1 525020 105 CAPACITOR SMD CERAMIC 4700pF 50V 10 o 9 R28 R29 R50 R51 4 525000 82525 RESISTOR SMD METAL FILM 1 10W82 5K 1 c5 1 825024 55 CAPACITOR SMD TANT ALUM 4 7MF 35V 10 c R30 R47 RBB FRO6 R97 R1 16124 7 525000 20025 RESISTOR SMD METAL FILM 1 10W 20 0K 1 06 039 48 3 525020 45 CAPACITOR SMD CERAMIC 820pF 50V 5 CO Clic R31 R35 2 _ 525000 26705 RESISTOR SMD METAL FILM 1 10W2670HMS C7 09 011 C14 C15 C17 C18 26 25020 3SMT CAPACITOR SMD CERAMIC 0 1MF 50V 10 X 5 5 R37 R45 2 518380 14 THERMISTOR PTC 5000HMS 28mA C19 22 C24 C27 C28 C29 11 R38 1 se5000 68135MT RESISTOR SMD METAL FILM 1 10W 681K 1 C32 C34 C35 C37 C38 C40 o 2 R39 R63 R79 R90 4 _ s25000 2210SMT RESISTOR SMD METAL FILM 1 10W 221 OHMS C41 C44 C47 C50 C52 53 054 cc R41 R64 2 525001 33215 RESISTOR SMD 3 32K 1 4W 1206 1 TR 1 525024 25 CAPACITOR SMD TANT ALUM 1 0MF 35V 10 R42 R122 2 _ 525000 10035 RESISTOR SMD MET AL FILM 1 10W 100K 1 C10 1 525020 125 CAPACITOR SMD CERAMIC t O0pF 100V 5 844 1 __ 525000 35705 RESISTOR SMD METAL FILM 1 10W3570HMS C12 C23 C30 C31 C36 C42 C43 6 S25020 2SMT CAPACITOR SMD CERAMIC 0 022MF 50V 10 R46 R80 RT15 3 5250
65. aken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lift ing chains crane cables or other alternate circuits This can cre ate fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c l CYLINDER may explode D if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc
66. aster TOC o o 0 iv z o tc Return to Master TOC G 1 ELECTRICAL DIAGRAMS G 1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION ELECTRICAL 5 0 SECTION G WIRING 14 G 2 CONTROL PC BOARD 27 G 3 CONTROL PC BOARD ASSEMBLY G 4 POWER MIG 200 LINCOLN G 2 ELECTRICAL DIAGRAMS POWER MIG 200 208 230V GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 WELDING CABLE MUST OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS CONTROL BOARD CAVITY NUMBERING SEQUENCE COLOR CODE THIS DIAGRAM SHOWS THE ELECTRODE POLARITY POSITIVE TO CHANGE POLARITY TURN COMPONENT SIDE OF P C BOARD B BLACK THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK W WHITE STUD R RED U BLUE Return to Section TOC Return to Master TOC INDICATES CONNECTOR CAVITY No TRANSFORMER THERMOSTAT THERMOSTAT CAVITY 36 NUMBERING SEQUENCE we ie ian NON LEAD SIDE OF CONNECTOR 56 J4 TRIGGER 106A MOTOR SIDE 1 4 108A 8 lt 0000 107A 7
67. ation and there is no open circuit voltage properly and in good condition good connections Return to Section TOC Return to Master TOC Make sure the output selector 2 Perform the Output Contactor Switch is in a good condition position and not between posi tions Perform the Output Bridge Rectifier Test Perform the Main Transformer Check the heavy current carry ing leads between the output selector switch output contac tor output bridge rectifier and the output terminals for loose or faulty connections See Wiring Diagram Ojo Fle 515 0 gt g 9 5 2 1 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 9 2 2 z F 6 TROUBLESHOOTING AND REPAIR Troubleshooting Guide see Wiring Diagrams for location of specified components and for troubleshooting of specific circuits POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT
68. ct lead 118 from the rear access panel See Figure F 21 Feed lead 118 toward the inside of the machine Cut any necessary cable ties Remove any necessary wiring harnesses Disconnect lead 121 See Figure 19 Using a 1 2 nutdriver remove the four main transformer mounting bolts and associated washers See Figure F 16 FIGURE F 16 MAIN TRANSFORMER LOCATION Main Transformer 1 2 Mounting Bolts POWER MIG 200 LINCOLN F 42 F 43 TROUBLESHOOTING AND REPAIR F 43 9 9 MAIN TRANSFORMER REPLACEMENT Continued 15 Carefully maneuver the main transformer 5 Reconnect lead X1 to the output diode 8 out the left side of the machine bridge rectifier NOTE Two people may be needed to maneu 6 Reconnect leads X8 X7 X6 X5 X4 X3 4 ver the main transformer out of the X2 previously removed from the switch 5 5 machine assembly 7 lead H1B and the other associat ed lead connected to the same terminal These leads are connected to the ON OFF 1 Carefully maneuver the new main trans Switch former back into the machine and onto its mounting studs 9 8 Replace any necessary cable ties and wiring 2 Using a 1 2 nutdriver mount the main trans harnesses IOrmer m proper position 9 Reconnect leads X9 X10 104B amp 104C 3 Reconnect leads 118 and 121 previously
69. d in J5 See the wiring diagram Check the gas source and hoses The machine stops feeding wire while welding When the gun trig ger is released and pulled again the wire feed starts for kinks or leaks Check for a mechanical restric tion in the wire feed path The gun may be clogged Make sure the drive rolls and guide plates are clean and are the correct size Check the spindle for ease of rotation F 7 Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION 1 Check plug J1 on the control board for loose or faulty connections See wiring diagram Check the gas solenoid by discon necting it from leads 108A and 116A amp B Apply 12VDC external supply to the solenoid If the sole noid does NOT activate then it may be faulty Replace Check the motor armature current Normal armature current is 2 0 to 2 7 amps maximum If the motor arma ture current is normal and the motor continues to shut off the control board may be faulty Replace If the motor armature current is high over 2 7 amps and there are NO restrictions in the wire feeding path then the motor or gearbox may be defective Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting
70. de from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 c Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especia
71. depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 9 Slide cage all the way onto the adapter until the retaining spring pops up fully A CAUTION CHECK TO BE SURE THE RETAINING SPRING HAS FULLY RETURNED TO THE LOCKING POSITION AND HAS SECURELY LOCKED THE READI REEL CAGE IN PLACE RETAINING SPRING MUST REST ON THE CAGE NOT THE WELDING ELECTRODE 10 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle FIGURE B 2 2 IN OD SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR GROOVES READI REEL c 2 INSIDE CAGE WIRES RELEASE BAR To Mount 10 to 44 Lb 4 5 20 kg Spools 12 300 mm Diameter or 14Lb 6 Kg Innershield Coils For 13 14 Ib 6 Kg Innershield coils a K435 Coil Adapter must be used 1 Open the Wire Drive Compartment Door 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 3 Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the back side of the spool Note an arrow mark on the spindle lines up with the brake holding pin to assist in lining up a hole Be certain the wire comes off the reel in a direction so as to de reel from the top of the coil 4 Re install the Retaining Collar Make sure that the Re
72. er TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the contactor is functional MATERIALS NEEDED Return to Section TOC Return to Master TOC 12 VDC Supply Volt Ohmmeter 7 16 Wrench This procedure takes approximately 30 minutes to perform Ojo Fle 515 0 218 5 2 Im Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC F 22 TROUBLESHOOTING AND REPAIR CONTACTOR TEST Continued TEST PROCEDURE 1 Remove the input power to the POWER MIG 200 machine 2 Using the 5 16 Nutdriver remove the tool tray 3 Locate and remove leads 106B 106C and 107A from the contactor coil terminals See Figure F7 See the Wiring Diagram 4 Using the 7 16 wrench remove one If the resistance is high or open 7 If the contactor activates when the 12VDC is applied check the resistance between the two large terminals with the contactor activated The resistance should be very low 0 to 1 ohm between the two large terminals when the contactor is activated the contactor is faulty Replace If the contactor activates and the resistance between the
73. eturn to Master TOC IDAIG TVA 20 5 22 0 222A 2 VAC 24 8 26 5 26 9 28 8 olo 12 If ALL the voltages tested are incorrect 13 If the correct nameplate voltage is being or missing test for correct nameplate applied to the main transformer and one ela input voltage between the H1 lead at the or more of the secondary voltages are T 9 ON OFF POWER SWITCH to H2 or H3 missing or are incorrect the main trans 5 at the reconnect panel Voltage tested former may be faulty Replace will vary depending on input voltage con c E nection See wiring diagram for test 14 When test is complete replace tool tray 2 point locations case sides and top aja A If the input voltage test is incorrect check for loose or broken leads between the reconnect panel and the ON OFF POWER SWITCH B Test the ON OFF POWER SWITCH for proper operation Ojo Fle 515 0 218 5 2 Im Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN F 15 TROUBLESHOOTING AND REPAIR F 15 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST WARNING 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 or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and
74. f the mounting bolts are replaced 5 Using a flathead screwdriver loosen the fan blade mounting band See Figure F 22 6 Pry the fan blade off of the mounting shaft NOTE If fan blade cracks or breaks 13 he putes Capacitor Bank upon removal replace it 14 Replace the lower right case cover Return to Section TOC Return to Master TOC 7 Carefully manuver the fan motor and fan blade out of the right side of the machine FIGURE F 22 FAN MOUNTING BOLTS REAR Fan Blade Ojo Fle 515 0 218 5 2 Im Mounting Band 11 32 Mounting Nuts 5 16 Bolts Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q Et 2 c 3 Return to Section Return to Master TOC 2 7 2 5 cc F 49 TROUBLESHOOTING AND REPAIR OUTPUT CONTACTOR REPLACEMENT WARNING 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 or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions
75. g Diagram 1 Disconnect main input power to the 4 Locate the black and white armature machine leads on plug J4 See Figure F 4 POWER MIG 200 LINCOLN F 17 TROUBLESHOOTING AND REPAIR F 17 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued 5 Make the following voltage tests WARNING 2 Locate plug J4 3 Locate the tach leads on plug J4 ELECTRIC SHOCK can kill Figure 5 Do not touch electrically live parts such as output terminals or internal wiring Return to Section TOC Return to Master TOC 4 Connect the main input power to the machine All input power must be electri cally disconnected before pro ceeding a Turn the machine OFF between each A WARNING test 0 ELECTRIC SHOCK can kill 5 Make the following voltage tests Return to Section TOC Ojo Fle 515 gt 218 5 2 Im Return to Section TOC Return to Master TOC Return to Master TOC b Carefully insert the meter probes into the lead side of plug J4 c Turn the machine ON and pull the gun trigger to conduct the voltage test FROM LEAD FROM LEAD FROM LEAD Black White 2 29 VDC Armature Armature varies depend ing on wire feed Lead Lead speed 6 If the voltage to the wire drive motor arma ture is zero check the wires between plug J4 and the wire drive motor Also check the electrical connector J5 for proper con nections and jumper plug
76. he main AC input power to 5 the machine BEAD VOLTAGE 2 Locate plug J4 and the tach leads Black BLUE 3 0 TO 4 0 See Figure F 5 VDC 3 Connect main input power to the machine 5 If the 3 0 to 4 0 VDC is present the tachometer circuit is sending the correct 4 Make the following voltage tests feedback signal to the control PC board Check the leads and plug J5 See the olo B E A WARNING Wiring Diagram 912 ELECTRIC SHOCK can kill 6 jf the 3 0 to 4 0 VDC is NOT present Do not touch electrically live or NOT correct the control PC board y parts such as output terminals is not receiving the proper feedback or internal wiring cle voltage from the tachometer circuit 5 5 input power must be electri 2 c E eee before pro 7 t the leads are okay the tachometer circuit may be faulty replace the a Turn the machine OFF between tachometer circuit each test 8 Replace the tool tray b Carefully insert the meter probes into the lead side of plug J4 See Figure F5 FIGURE F 5 PLUG J4 Black Black Tach Arm White Ojo E 515 0 2 2 5 2 Im cate 515 518 5 gt 2 m Red Blue cle Tach Tach 515 5 dc POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q
77. id 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 INSTALLATION A 3 INPUT POWER GROUNDING AND CONNECTION DIAGRAMS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring 0 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 for dual voltage machines and Figure A 2 for triple voltage machines WARNING Make certain that the input power is electrically d
78. if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 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 287 standards Use suitable clothing ma
79. il fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 14 Do not put your hands near the engine fan Do not e attempt to override the governor or idler by push ing on the throttle control rods while the engine is running AX To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known
80. ing Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machinery may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped according to feeding problems and function problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted without removing the case wrap around cover The last column labeled RECOMMENDED COURSE OF ACTION lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either bad or good If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All the necessary test specifications and repair procedures are described in detail following the troubleshooting guide All electrical test points terminal strips junctions etc can be found on the electrical wiring diagrams and schematics in the Electrical Diagram Section
81. isconnected before removing the screw on the reconnect panel access cover POWER MIG 200 LINCOLN amp A 4 INSTALLATION A 4 FIGURE A 1 Dual Voltage Machine Input Connections INPUT SUPPLY CONNECTION DIAGRAM WARNING Disconnect input power before inspecting or servicing machine Connect transformer input lead for desired voltage SINGLE PHASE 60 HZ Return to Section TOC Return to Master TOC Do not operate with covers removed ELECTRIC SHOCK Do not touch electrically live parts Only qualified persons should install Return to Section TOC Ojo o Fle 5 5 0 gt Im Return to Section TOC Return to Master TOC Return to Master TOC CAN KILL use or service this equipment Install and Ground machine per National Electrical Code and local codes Use Grounding Stud Lug inside Use CU wire only Consult Instruction Manual before installing or operating 3 The 208 230 volt 60 Hz model POWER MIG is shipped with a 7 ft input cable and plug connected to the welder The 230 460 575 volt 60 Hz model is not equipped with an input cable or a plug 230 V 208 V Using the instructions in Figure have quali fied electrician connect a receptacle Customer Supplied or cable to the input power lines and the system ground per the U S National Electrical Code and any applicable local codes
82. ith a single connecting plug and trigger switch a rear gas inlet fitting hose solenoid valve assembly and mounting hardware with installation and operation instructions A WARNING Remove all input power to the POWER MIG 200 before installing the Spool Gun and Kit POWER MIG 200 LINCOLN ACCESSORIES MAKING WELD WITH THE SPOOL GUN 5 To return to normal POWER MIG 200 welding ADAPTER KIT AND SPOOL GUN release the spool gun trigger set spool gun selector INSTALLED switch to normal and reset feeder gun voltage pro cedure setting if necessary 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 Return to Section TOC Return to Master TOC 1 Setting spool gun selector switch to the Normal position and pulling the trigger for the built in feeder 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 Return to Section TOC Return to Master TOC 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 e Enables spool gun operation and spool gun gas solenoid valve C
83. king Weld with the Spool Gun Adapter Kit C 3 Return to Master TOC o o 0 iv z o tc Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo O10 E 515 0 2 2 5 2 Im Return to Section TOC Return to Master TOC 2 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 Drive Roll Kit _ 023 030 0 6 0 8 mm Solid Phe 1035 0 9 mm 045 1 2 mm 1696 0305 KP1696 035S KP1696 045S KP1697 035C KP1697 045C 035 0 9 mm Cored 045 1 2 mm TABLE 3 64 1 2 mm ALUMINUM FEEDING KIT K1703 1 KP1695 3 64A This kit helps push feeding aluminum through standard machine feeder and gun It provides gun and wire drive conversion parts to weld with 3 64 1 2 mm aluminum wire 5356 alloy aluminum wire is recommended for best push feeding performance Kit includes drive rolls and wire guide plate for the wire drive liner and two contact tips for the gun along with installation instructions K363P READI REEL ADAPTER The K363P Readi Reel Adapter mounts to the 2 spin dle It is needed to mount the 22 30 Ib Readi Reels DUAL CYLINDER MOUNTING KIT
84. lease Bar pops up and that the collar retainers fully engage the retaining ring groove on the spindle TO START THE WELDER Turn the Power Switch switch to ON This lights the red LED dis play lights With the desired voltage and wire speed selected oper ate the gun trigger for welder output and to energize the wire feed motor POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo O10 Fle 515 218 5 2 1 Return to Section Return to Master TOC Return to Master TOC B 5 FEEDING WIRE ELECTRODE WARNING 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 Refer to Table C 1 in Accessories section 1 Turn the Readi Reel or spool until the free end of the electrode is accessible 2 While securely holding the electrode cut off the bent end and straighten the first six inches If the elec trode is not properly straightened it may not feed properly through the wire drive system 3 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 Leave
85. lenoid NOTE Unshaded areas of block logic diagrams are the subject of discussion POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo Fle 515 0 gt 218 JE 2 Im Return to Section TOC Return to Master TOC E 3 THEORY OF OPERATION E 3 FIGURE E 3 CONTROL CIRCUITS WIRE GAS SPEED SOLENOID CONTROL TRANSFORMER OUTPUT BRIDGE THERMOSTAT THERMOSTAT FEEDBACK LINE SWITCH TAP SELECTOR GUN TRIGGER SWITCH CONTACTOR CONTROL GUN ASSEMBLY LE OUTPUT POSITIVE CHOKE TERMINAL CONTACTOR CAPACITORS iu RECONNECT MAIN PANEL TRANSFORMER OUTPUT RECTIFICATION CONTACTOR AND CONTROL BOARD The AC voltage developed on the secondary winding is applied through the selector switch and output contactor to the output rectifier bridge This DC welding voltage is filtered by the output capacitors and applied to the output terminals and welding gun Since the output choke is in series with the positive leg of the output rectifier and also in series with the gun and welding load a filtered constant voltage output is applied to the output terminals of the machine NOTE Unshaded areas of block logic diagrams are the subject of discussion POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Retur
86. lly in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 POWER MIG 200 LINCOLN Return to Master TOC Return to Master TOC o o 77 iv o 4 c tc Return to Master TOC SAFETY WELDING SPARKS gt 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site Special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been t
87. losing spool gun trigger starts spool gun weld ing and makes both electrodes electrically 3 Operation with POWER MIG 200 the POWER MIG 200 input power ON Ojo E 515 0 2 2 5 2 Im e Adjusting the voltage tap control will increase or decrease your welding voltage e 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 Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN C 4 S T k EE Z E O DOL Je1Se A 0 UIN HY DOL Je1Se A 0 DOL J91Se N 01 DOL 181SEIN 01 DOL uonoes uumeg DOL uonoes uumeg DOL uonoes uumeg DOL uonoes Section D TABLE OF CONTENTS Section D MAINTENANCE SECTION O 1i E PP Section D Safety Precautions D 2 General Maintenance D 2 E Drive Rolls and Guide Plates D 2 Contact Tip and Gas Nozzle Installation D 2 Gun Tubes
88. n A 3 Input Power Grounding and Connection Diagrams A 3 Dual Voltage Machine Input Connections 4 Triple Voltage Machine Input Connections 5 Output Polarity Connections A 5 Gun and Cable Installation A 6 Shielding A 6 Return to Master TOC o o 0 iv z o tc Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo Fle 515 0 gt 88 Im Return to Section TOC Return to Master TOC 2 INSTALLATION A 2 TECHNICAL SPECIFICATIONS POWER 200 INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 150 Amp Rated Output Input Current 150 Amp Rated Output 208 230 60 Hz 28 26 Amps 36 33 RATED OUTPUT Amps Volts at Rated Amperes 200 Amps 22 Volts 180 Amps 23 Volts 150 Amps 24 Volts OUTPUT Welding Current Range Maximum Open Circuit Voltage Welding Voltage Range 30 200 Amps 40 Volts 13 5 22 Volts RECOMMENDED INPUT WIRE AND FUSE SIZES 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
89. n to Master TOC 515 0 gt 2 Im Return to Section TOC Return to Master TOC E 4 THEORY OF OPERATION E 4 FIGURE E 4 OPTIONAL CIRCUITS WIRE GAS SPEED SOLENOID CONTROL CONTROL BOARD TRANSFORMER OUTPUT BRIDGE FEEDBACK THERMOSTAT THERMOSTAT TAP SELECTOR GUN TRIGGER SWITCH CONTACTOR CONTROL GUN ASSEMBLY LH OUTPUT POSITIVE CHOKE TERMINAL CONTACTOR RECONNECT MAIN PANEL TRANSFORMER NEGATIVE TERMINAL CONTROL BOARD GUN TRIGGER AND WIRE DRIVE MOTOR When the control board receives an activation command from the trigger circuit the control board activates the gas solenoid output contactor and the wire drive motor The control board monitors the motor s tach feedback signals and compares these to the wire speed control setting The proper armature voltage is then applied to the wire drive motor The drive motor speed is thus controlled which in turn regulates the electrode wire feed speed through the gun Two thermostats are included in the trigger circuitry If either of these thermostats would open the trigger circuit would be interrupted and the machine s output would be disabled NOTE Unshaded areas of block logic diagrams are the subject of discussion POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo Fle 5 0
90. ng a 7 16 wrench remove the three mounting bolts from the output contactor Note washer positions for replacement Figure F 24 Return to Section TOC Return to Master TOC FIGURE F 23 OUTPUT CONTACTOR LEADS Ojo Fle 515 218 5 2 Im Output Contactor Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN F 51 TROUBLESHOOTING AND REPAIR F 51 OUTPUT CONTACTOR REPLACEMENT Continued FIGURE F 24 OUTPUT CONTACTOR MOUNTING BOLTS Return to Section TOC Return to Master TOC 7 16 Mounting Bolts Return to Section TOC Return to Master TOC 19 2 7 2 5 cc o E 5 B Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN F 52 TROUBLESHOOTING AND REPAIR F 52 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts Herts Maximum Idle Amps Maximum Idle Watts Return to Section TOC Return to Master TOC OPEN CIRCUIT VOLTAGE 35 40 VDC WIRE SPEED RANGE 50 700 IPM 1 27 17 8 m minute Return to Section TOC Return to Master TOC Ojo Fle 515 0 218 JE 2 Im Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Master TOC Return to M
91. ng procedure will aid the technician in removing the main transformer for repair or replacement MATERIALS NEEDED 3 8 Nutdriver 716 Nutdriver 1 2 Nutdriver 5 16 Nutdriver Flathead Screwdriver This procedure takes approximately 80 minutes to perform POWER MIG 200 LINCOLN F 41 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o E 5 B Return to Section TOC Return to Master TOC 2 7 2 5 cc Locate the main transformer TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT Continued PROCEDURE Using a 3 8 nutdriver remove both sides of the case wraparound cover Using a 5 16 nutdriver remove the tool tray See Figure F 16 Label and disconnect leads X9 X10 104B amp 104C See Figure F 17 Using a flathead screwdriver Label and dis connect lead H1B and other associated lead connected to the same terminal These leads are connected to the ON OFF switch See Figure 17 Using a 7 16 nutdriver Label and discon nect leads X8 X7 X6 X5 X4 X3 amp X2 from the switch assembly Note washer position upon removal See Figure 18 T Using a 1 2 nutdriver label and remove lead X1 from the output diode bridge rectifi er Using a 5 16 Nutdriver open the rear access panel See Figure F 20 Disconne
92. nt until tip of screw no longer protrudes into gun opening as seen from front of machine 3 Insert the male of gun cable into the female casting through opening in front panel Make sure connector is fully inserted and tighten knurled Screw 4 Connect the gun trigger connector from the gun and cable to the mating receptacle inside the compart ment located above the gun connection made in item 3 above Make sure that the keyways are aligned insert and tighten retaining ring SHIELDING GAS For Gas Metal Arc Welding Processes Customer must provide cylinder of appropriate type shielding gas for the process being used A gas flow regulator for Argon blend gas and an inlet gas hose are factory provided with the POWER MIG 200 When using 100 CO an additional adapter will be required to connect the regulator to the gas bottle WARNING CYLINDER may explode if damaged Gas under pressure is explosive Always keep gas cylinders in an upright position and always keep chained to undercarriage or stationary support See American National Standard Z 49 1 Safety Welding and Cutting published by the American Welding Society Install shielding gas supply as follows 1 Set gas cylinder on rear platform of POWER MIG 200 Hook chain in place to secure cylinder to rear of welder INSTALLATION A 6 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt du
93. om of the machine These bolts can be accessed easily from the bottom of the machine 7 12 Reconnect the four thick black leads previously See Figure 13 labeled and removed using a 1 2 nutdriver 6 Carefully manipulate the output diode bridge rectifier and the mounting bracket out of the left side of the machine 11 Reconnect leads 104A and 104B previously removed Return to Section TOC Return to Master TOC 13 Replace the left side of the case wraparound cover FIGURE F 12 OUTPUT DIODE BRIDGE RECTIFIER LOCATION OUTPUT DIODE BRIDGE RECTIFIER Ojo E 5 5 0 2 2 5 2 Im Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o E 5 B Return to Section TOC Return to Master TOC 2 7 2 5 cc F 35 TROUBLESHOOTING AND REPAIR F 35 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT CONTINUED FIGURE 13 OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET 5 16 Mounting Bracket Mounting Bolts Mounting Bolts Bracket POWER MIG 200 LINCOLN F 36 S T k EE Z E ub DOL Je1Se A 0 NOL Je1Se A 0 DOL J91Se N 01 DOL 181SEIN 0
94. on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles 7 Quand on ne soude pas poser la pince une endroit isol
95. one side 8 The flow regulator is adjustable Adjust it to the flow rate recommended for the procedure and process being used before making the weld POWER MIG 200 LINCOLN amp Section B TABLE OF CONTENTS Section B OPERATION SECTION wc on Aer Section B Warnings 22 224 2 Product Description B 3 5 Recommended Processes and Equipment B 3 d Welding Capability B 3 Limitations xut mg IC RR wa RUE en ES B 3 Description of Controls B 3 Wire Drive Roll cesas se Bele REX EE ER 4 E ROC a de B 3 Wire Size Conversion Parts B 3 Procedure for Changing Drive and Idle Roll Sets B 4 Wire Reel Loading B 4 To Start the Welder B 4 Feeding Wire Electrode B 5 e Idle Roll Pressure Setting B 5 Making Weld B 5 5 Avoiding Wire Feeding Problems B 6 2 Fan Control 7 44 xd Rug aime tiers 6 Input Line Voltage Variations B 6 2 Wirefeed Overload Protection
96. ould not be installed in another gun unless it can meet the liner cut off length requirement Liners are shipped with the jacket of the liner extended the proper amount 1 Remove the gas nozzle and nozzle insulator if used to locate the set screw in the gas diffuser which is used to hold the old liner in place Loosen the set screw with a 5 64 2 0 mm Allen wrench 2 Remove the gas diffuser from the gun tube 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 3 64 1 2 mm S19418 3 S19418 1 8 Tighten the set screw in the side of the gas diffuser against the cable liner using a 5 64 2 0 mm Allen wrench FIGURE D 1 SET SCREW BRASS CABLE CONNECTOR iia 31 8mm LINER SET SCREW GAS NOZZLE INSULATOR IF USED 39 S This screw should only be gently tightened Overtightening will split or collapse the liner and cause poor wire feeding GAS NOZZLE POWER MIG 200 LINCOLN D 4 MAINTENANCE D 4 9 9 GUN HANDLE DISASSEMBLY TABLE D 2 ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS 5 5 The internal parts of the gun handle may be FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES 9 2 inspected or serviced if necessary English Metric Description Part No Size Size 8 8 handle consists of two halves that CABLE LINER
97. precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the wire drive motor and voltage feedback circuit are functioning properly MATERIALS NEEDED Return to Section TOC Return to Master TOC 5 16 Nutdriver Volt Ohmmeter This procedure takes approximately 30 minutes to perform Ojo Fle 515 0 218 5 2 Im Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo Fle 515 0 218 5 2 Im Return to Section TOC Return to Master TOC F 16 TROUBLESHOOTING AND REPAIR F 16 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued FIGURE F 4 PLUG J4 Black Black Tach Arm White Qo Red Blue Tach Tach TEST PROCEDURE NOTE POLARITY MUST BE OBSERVED 2 Open the side panels and remove the FOR THESE TESTS tool tray using a 5 16 nutdriver Test for correct wire drive motor armature 3 Locate plug J4 on the wiring harness voltage See Wirin
98. r There is no circuit breaker to reset as the protection is done with reliable solid state electronics POWER MIG 200 LINCOLN E 6 S T k EE Z E LL NOL Je1Se A 0 NOL Je1Se A 0 uunjeu DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes DOL uonoes Section F TABLE OF CONTENTS Section F TROUBLESHOOTING AND REPAIR SECTION O 5 o E Troubleshooting and Repair Section F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures F 3 5 Troubleshooting Guide F 4 d Test Procedures F 11 Main Transformer Test F 11 Wire Drive Motor and Tachometer Feedback Test F 15 Output Bridge Rectifier Test F 19 Contactor Test F 21 Voltage Waveforms F 23 Component Replacement Procedures F 27 Control Board Replacement F 27 Wire Drive Motor Assembly Replacement F 29 e Output Diode Bridge Rectifier Replacement F 33 Output Capacitors Replacement
99. r Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number Page Number if necessary Your Company Your Name Please give detailed description below SD287 01 99 LINCOLN 5
100. roceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output diode bridge rectifier for repair or replacement MATERIALS NEEDED 3 8 Nutdriver 1 2 Nutdriver 5 16 Nutdriver This procedure takes approximately 50 minutes to perform POWER MIG 200 LINCOLN F 33 F 34 TROUBLESHOOTING AND REPAIR F 34 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT CONTINUED PROCEDURE 7 Using a 1 2 nutdriver remove the three bolts mounting the bracket to the rectifier The rectifi er is now ready for repair or replacement Figure F 13 2 Locate the output diode bridge rectifier See 8 Mount the new rectifier to the mounting bracket Figure F 12 a using the three 1 2 bolts 1 Using a 3 8 nutdriver remove the left side of the case wraparound cover Return to Section TOC Return to Master TOC 3 Using a 1 2 nutdriver label and remove the four thick black leads connected to the rectifier NOTE Be sure to label lead terminals also Take note of washer placement upon removal 9 Carefully manipulate the rectifier and mounting bracket as a one back into the machine to its proper location 4 Label and remove leads 104A and 104B See 10 Mount the unit to the bottom of the machine Wiring Diagram using the four 516 mounting bolts previously removed 5 Using a 5 16 nutdriver locate and remove the four bolts mounting the rectifier bracket to the bott
101. s Figure F 11 hose from the bottom of the wire drive See Figure F 10 7 Carefully maneuver the wire drive assem bly out the side of the machine to gain access to plug J4 See Wiring Diagram 1 Remove power to the machine 2 Lift cover to gain access to the wire drive See Figure F 9 4 Using a 9 16 nut driver remove the thick black positive lead located just above the gas hose See Figure 10 8 Disconnect plug J4 NOTE Disconnect lead from the wire drive motor assembly not the machine E 5 5 0 2 2 5 1 Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 5 0 218 5 2 Im Return to Section TOC Return to Master TOC F 31 TROUBLESHOOTING AND REPAIR F 31 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Continued FIGURE 10 WIRE DRIVE HOSE amp LEAD LOCATION 5 16 Monuting Screws 5 16 Sheet Metal Screws 9 16 Bolt Gas Hose FIGURE F 11 MOUNTING SCREW LOCATIONS POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o E 5 B Return to Section TOC Return to Master TOC 2 7
102. se observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct voltages are being applied a Applied to the primary windings of the main transformers b Induced on the secondary and auxiliary windings of the main transformer MATERIALS NEEDED 3 8 Nutdriver 5 16 Nutdriver Volt ohmmeter This procedure takes approximately 40 minutes to perform POWER MIG 200 LINCOLN F 11 F 12 TROUBLESHOOTING AND REPAIR F 12 MAIN TRANSFORMER TEST continued FIGURE F 1 OUTPUT SELECTOR SWITCH TERMINALS x2 X3 X4 X5 x6 X7 x Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TEST PROCEDURE 6 Locate leads X9 and X10 WARNING 7 Connect main input power to the THE ON OFF POWER SWITCH will be Machine REF during tese Tesis 8 Turn the POWER MIG 200 ON OFF NOTE Secondary voltages will vary Power Switch to the ON position proportionately with the primary input voltage WARNING ELECTRIC 5 can kill Do not touch electrically live parts such as output terminals or internal wiring o
103. so check for leaky capacitors Replace if necessary WARNING The liquid electrolyte in these capacitors is toxic Avoid contact with any portion of your body 3 The output selector switch may be faulty Check for good con tact and continuity zero ohms through the switch See the Wiring Diagram 4 Perform the Output Contactor 5 Perform the Output Bridge Rectifier Test 6 Perform the Ouiput Contacto CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 POWER MIG 200 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Ojo Fle 515 0 gt g 9 5 2 Im Return to Section TOC Return to Master TOC Return to Master TOC F 7 TROUBLESHOOTING AND REPAIR Troubleshooting Guide see Wiring Diagrams for location of specified components and for troubleshooting of specific circuits PROBLEMS SYMPTOMS There is no gas flow when the gun 1 trigger is activated The wire feeds and the arc voltage is present FUNCTION PROBLEMS If a spool gun adapter is installed make certain the toggle switch in the spool gun kit in the correct position 1 a spool gun adapter is NOT installed make certain the jumper plug is installe
104. st oil or grease Remove dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve outlet WARNING Be sure to keep your face away from the valve out let when cracking the valve 4 Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench NOTE If connecting to 100 CO cylinder an additional regulator adapter must be installed between the regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seat ed for connection to the CO cylinder 5 Attach one end of the inlet gas hose to the outlet fit ting of the flow regulator the other end to the POWER MIG 200 rear fitting and tighten the union nuts securely with a wrench 6 Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released 7 Standing to one side open the cylinder valve slow ly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully WARNING Never stand directly in front of or behind the flow regulator when opening the cylinder valve Always stand to
105. t bag and perform the following procedures PC board damaged by electricity can be static Remove your body s static charge before ATTENTION opening the static Static Sensitive shielding bag Wear anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame Devices Handle only at Static Safe Workstations If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shield ing bag and place it directly into the equip ment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shielding bag f the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board a
106. to Master TOC POWER MIG 200 LINCOLN F 25 TROUBLESHOOTING AND REPAIR F 25 ABNORMAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED G ONE OUTPUT DIODE NOT FUNCTIONING Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MACHINE LOADED TO 180 AMPS AT 16 VDC SCOPE SETTINGS This is NOT a typical DC output voltage waveform One output diode is not func Volts Div tioning Note the increased ripple con tent One diode was disconnected to Horizontal Sweep simulate an open or non functioning out put diode Each vertical division repre Coupling sents 20 volts and each horizontal divi sion represents 5 milliseconds in time f Trigger The machine was loaded with a resis tance grid bank Ojo Fle 515 0 218 5 2 Im NOTE Scope probes connected at machine output terminals probe to electrode probe to work Return to Section TOC Return to Master TOC POWER MIG 200 LINCOLN F 26 TROUBLESHOOTING AND REPAIR F 26 ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING G Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC SCOPE SETTINGS This is NOT a typical DC output voltage waveform The output capacitors are Volts Div not functioning Note the lack of filter ing in the output waveform
107. vailable for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims POWER MIG 200 LINCOLN F 3 4 TROUBLESHOOTING AND REPAIR F 4 Troubleshooting Guide see Wiring Diagrams for location of specified components and for troubleshooting of specific circuits Observe Safety Guidelines detailed in the beginning of this manual Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PROBLEMS SYMPTOMS Major physical or electrical damage is evident The machine is dead no open 1 circuit voltage and no
108. wire feed when the gun trigger is activated The cooling fan is not running There is no open circuit voltage or wire feed when the gun trigger is activated The cooling fan is running 1 Contact your local OUTPUT PROBLEMS Lincoln Electric authorized field service facility Make certain the input power switch S1 is in the ON position Check the input voltage at the machine The input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input lines Make sure the input voltage is correct and matches the nameplate rating and reconnect panel configuration One of the two thermostats may be open due to machine overheating If the machine operates normally after a cooling off period then check for proper fan operation and ventilation Make certain the machine s duty cycle is not being exceeded 1 Contact 4 The POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION Lincoln Electric Service Department 1 800 833 9353 WELD 1 Check the input power switch S1 It may be faulty 2 Check for broken or missing wires at the reconnect panel 3 Perform the Main Transformer 1 The baffle mounted rectifier bridge may be faulty Chec and replace if necessary 2 Perform Transformer 3 Check the thermostats and associated leads for loose or faulty connections See the wiring diagram internal
109. y 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 ambi ent temperature plus overload The thermostats auto matically reset when the temperature reaches a safe operating level and welding and feeding are allowed again when gun is retriggered TABLE B 1 Steel Thickness Wire Feed Speed Voltage Tap ing S Wire Dia Gas WireType Polarity 18 6 gage 14 2 gage 10gage 3 16 5 16 3 8 1 2 Outershield 3 4 ESOT Note Requires Multiple Pass 045 T Electrical Stickout 250 D 300 E 350 F 00 6 500 G 300 E 350 F 00 G 200 E 225 F 250 G 250 6 250 G 80 B 90 C 110 D 130 E 60 B 90 10 130 E 150 150 NR 211 15 only recommended for a maximum of 5 16 POWER MIG 200 LINCOLN Section C TABLE OF CONTENTS Section C ACCESSORIES SECTION O Accessorles Section Drive Roll Kits ene opere RR eg oe ER E des C 2 3 64 1 2mm Aluminum Feeding Kit K1703 1 C 2 5 K363P Readi Reel Adapter G2 d Dual Cylinder Mounting C 2 Alternative Magnum GMAW Gun and Cable Assemblies C 2 Magnum Gun Connection Kit C 2 Spool Gun and Adapter Kit C 2 Ma

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