IM693

POWER MIG™ 200 June, 2002

For use with machine Code Numbers 10564

For use with machine Code Numbers

This manual covers equipment which is no

longer in production by The Lincoln Electric Co.
Specifications and availability of optional
features may have changed.

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

OPERATOR’S MANUAL

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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, 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 & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________

1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95
POWER MIG 200
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.

3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.g. Never dip the electrode in water for cooling. ucts.

3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

POWER MIG 200

iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
• Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
• A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances”, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or cylinders, associated equipment, and CGA publication P-l,
welding. They may explode. “Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil 1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding 8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building switch at the fuse box before working on
framework or other locations away from the welding area the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir- 8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains Electrical Code, all local codes and the manufacturer’s
or cables until they fail. recommendations.

6.h. Also see item 1.c. 8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

POWER MIG 200

iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
a. Les circuits à l’électrode et à la piéce sont sous tension de la zone de travail qu’il est pratique de le faire. Si on place
quand la machine à souder est en marche. Eviter toujours la masse sur la charpente de la construction ou d’autres
tout contact entre les parties sous tension et la peau nue endroits éloignés de la zone de travail, on augmente le risque
ou les vétements mouillés. Porter des gants secs et sans de voir passer le courant de soudage par les chaines de lev-
trous pour isoler les mains. age, câbles de grue, ou autres circuits. Cela peut provoquer
b. Faire trés attention de bien s’isoler de la masse quand on des risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher câbles jusqu’à ce qu’ils se rompent.
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à souder du solvant pour produire du phosgéne (gas fortement toxique)
parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions voir le code “Code for safety in welding and cutting” CSA
pour le porte-électrode s’applicuent aussi au pistolet de Standard W 117.2-1974.
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
PRÉCAUTIONS DE SÛRETÉ POUR
du corps. LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, TRANSFORMATEUR ET À
donc: REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les Mar. ‘93

POWER MIG 200

v v

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.

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

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

CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS vi

Page

Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions.................................................................................................A-2
Uncrating the POWER MIG 200 ............................................................................A-2
Location .................................................................................................................A-2
Input Power, Grounding and connection Diagrams .................................A-2 thru A-3
Output Polarity Connections ..................................................................................A-3
Gun and Cable Installation ....................................................................................A-4
Shielding Gas ........................................................................................................A-4

Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
Product Description ...............................................................................................B-2
Recommended Processes and Equipment ...........................................................B-2
Welding Capability .................................................................................................B-2
Limitations..............................................................................................................B-2
Description of Controls ..........................................................................................B-2
Wire Drive Roll.......................................................................................................B-2
Wire Size Conversion parts ...................................................................................B-2
Procedure for Changing Drive Roll ........................................................................B-3
Wire Reel Loading .................................................................................................B-3
Mounting of 10 to 30 lbs. Spools ...........................................................................B-3
To Start the Welder................................................................................................B-3
Feeding Electrode..................................................................................................B-4
Idle Roll Pressure Setting ......................................................................................B-4
Making a Weld .......................................................................................................B-4
Avoiding Wire Feeding Problems ..........................................................................B-5
Fan Control ............................................................................................................B-5
Input Line Voltage Protection.................................................................................B-5
Wire Feed overload Protection ..............................................................................B-5
Welding Thermal Overload Protection...................................................................B-5

Accessories .....................................................................................................Section C
Drive Roll Kits ........................................................................................................C-1
Aluminum Feeding Kit (Optional K1703-1) ............................................................C-1
K363P Readi-Reel Adapter ...................................................................................C-1
Dual Cylinder Mounting Kit (K1702-1) ...................................................................C-1
Alternative Magnum GMAW Gun and Cable Assemblies .....................................C-1
Magnum Gun Connection Kit (Optional K466-6) ...................................................C-1
Spool Gun and Adapter Kit (Optional K1809-1) ....................................................C-1
Making a Weld with the Spool Gun Adapter Kit and Spool Gun Installed .............C-2

POWER MIG 200

vii MASTER TABLE OF CONTENTS FOR ALL SECTIONS (cont.) vii

Page

Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Maintenance ............................................................................................D-1
Drive Rolls and guide Tubes .................................................................................D-1
Contact Tip and Gas Nozzle Installation ...............................................................D-1
Gun Tubes and Nozzles ........................................................................................D-1
Cable Cleaning ......................................................................................................D-1
Liner Removal and Replacement ..........................................................................D-2
Gun Handle Disassembly ......................................................................................D-3

Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ............................................................................E-2 thru E-4

Wiring Diagram and Dimension Print ............................................................Section F

Parts Manual ....................................................................................................Appendix

POWER MIG 200 ..................................................................................P372 Series
Magnum 250L Gun .....................................................................................P202-H.2

POWER MIG 200

A-1 INSTALLATION A-1

TECHNICAL SPECIFICATIONS – POWER MIG 200

INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current @ 150 Amp Rated Output Input Current @ 150 Amp Rated Output
208/230/50/60 Hz 28/26 Amps 36/33

RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
30% 200 Amps 22 Volts
40% 180 Amps 23 Volts
60% 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
Frequency (Hz) Size (Super Lag) Nameplate up to 100 ft.) exceeding 100 ft.)
208/50/60 60 36 10 (6 mm2) 8 (10 mm2)
230/50/60 60 33 10 (6 mm2) 8 (10 mm2)

NOTE: Use #10 AWG Grounding Wire

PHYSICAL DIMENSIONS
Height Width Depth Weight
31.79 in 18.88 in 38.78 in 210 Ibs
808 mm 480 mm 985 mm 95 kg

WIRE SPEED RANGE

Wire Speed 50 – 700 IPM (1.27 – 17.8 m/minute)

POWER MIG 200

A-2 INSTALLATION A-2

Read entire installation section before starting INPUT POWER, GROUNDING AND
installation. CONNECTION DIAGRAMS
SAFETY PRECAUTIONS
WARNING
WARNING ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as
ELECTRIC SHOCK can kill. output terminals or internal wiring.
• Only qualified personnel should perform • All input power must be electrically dis-
this installation. connected before proceeding.
• Only personnel that have read and under-
stood the POWER MIG 200 Operating
Manual should install and operate this 1. Before starting the installation, check with the local
equipment. power company if there is any question about
• Machine must be grounded per any nation- whether your power supply is adequate for the volt-
al, local or other applicable electrical age, amperes, phase, and frequency specified on
codes. the welder nameplate. Also be sure the planned
• The POWER MIG power switch is to be in installation will meet the U.S. National Electrical
the OFF position when installing work Code and local code requirements. This welder
cable and gun and when connecting other
may be operated from a single phase line or from
equipment.
one phase of a two or three phase line.

UNCRATING THE POWER MIG 200 2. Models that have multiple input voltages specified
on the nameplate (e.g. 208/230) are shipped con-
Cut banding and lift off cardboard carton. Cut banding nected for the highest voltage. If the welder is to be
holding the machine to the skid. Remove foam and operated on lower voltage, it must be reconnected
corrugated packing material. Untape accessories from according to the instructions in Figure A.1 for dual
Gas Bottle Platform. Unscrew the two wood screws voltage machines and Figure A.2 for triple voltage
(at the Gas Bottle Platform) holding the machine to machines.
the skid. Roll the machine off the skid assembly.

WARNING
LOCATION
Make certain that the input power is electrically
Locate the welder in a dry location where there is free disconnected before removing the screw on the
circulation of clean air into the louvers in the back and reconnect panel access cover.
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.

POWER MIG 200

A-3 INSTALLATION A-3

FIGURE A.1 — Dual Voltage Machine Input Connections

50/60 HZ

3. The 208/230 volt 50/60 Hz model POWER MIG is FIGURE A.3 — Receptacle Diagram
shipped with a 7 ft. input cable and plug connected
to the welder. CONNECT TO A SYSTEM
GROUNDING WIRE. SEE
THE UNITED STATES
4. Using the instructions in Figure A.3, have a quali- NATIONAL ELECTRICAL
fied electrician connect a receptacle (Customer CODE AND/OR LOCAL
Supplied) or cable to the input power lines and the CODES FOR OTHER
DETAILS AND MEANS FOR
system ground per the U.S. National Electrical PROPER GROUNDING.
Code and any applicable local codes. See
“Technical Specifications” at the beginning of this CONNECT TO HOT WIRES
OF A THREE-WIRE, SINGLE
chapter for proper wire sizes. For long runs over PHASE SYSTEM OR TO ONE
100 feet, larger copper wires should be used. Fuse PHASE OF A TWO OR
the two hot lines with super lag type fuses as THREE PHASE SYSTEM.
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 OUTPUT POLARITY CONNECTIONS
grounding of the welder frame when the welder
plug is inserted into a grounded receptacle. The welder, as shipped from the factory, is connected
for electrode positive (+) polarity. This is the normal
FIGURE A.3 — Receptacle Diagram polarity for GMA welding.

CONNECT TO A SYSTEM If negative (–) polarity is required, interchange the

GROUNDING WIRE. SEE THE connection of the two cables located in the wire drive
UNITED STATES NATIONAL
ELECTRICAL CODE AND/OR compartment near the front panel. The electrode
LOCAL CODES FOR OTHER cable, which is attached to the wire drive, is to be con-
DETAILS AND MEANS FOR nected to the negative (–) labeled terminal and the
PROPER GROUNDING.
work lead, which is attached to the work clamp, is to
CONNECT TO HOT WIRES be connected to the positive (+) labeled terminal.
OF A THREE-WIRE, SINGLE
PHASE SYSTEM OR TO ONE
PHASE OF A TWO OR
THREE PHASE SYSTEM.

POWER MIG 200

A-4 INSTALLATION A-4
2. Remove the cylinder cap. Inspect the cylinder
GUN AND CABLE INSTALLATION valves and regulator for damaged threads, dirt,
dust, oil or grease. Remove dust and dirt with a
The Magnum 250L gun and cable provided with the clean cloth.
POWER MIG 200 is factory installed with a liner for
.035-.045" (0.9-1.2 mm) electrode and an .035" (0.9 DO NOT ATTACH THE REGULATOR IF OIL,
mm) contact tip. Be sure that the contact tip, liner, and GREASE OR DAMAGE IS PRESENT! Inform your
drive rolls all match the size of the wire being used. gas supplier of this condition. Oil or grease in the
presence of high pressure oxygen is explosive.
WARNING
3. Stand to one side away from the outlet and open
Turn the welder power switch off before installing the cylinder valve for an instant. This blows away
gun and cable. any dust or dirt which may have accumulated in
the valve outlet.
1. Lay the cable out straight.
WARNING
2. Unscrew knurled screw on the drive unit front end
(inside wire feed compartment) until tip of screw no Be sure to keep your face away from the valve
longer protrudes into gun opening as seen from outlet when “cracking” the valve.
front of machine.

3. Insert the male end of gun cable into the female 4. Attach the flow regulator to the cylinder valve and
casting through opening in front panel. Make sure tighten the union nut(s) securely with a wrench.
connector is fully inserted and tighten knurled
screw. NOTE: If connecting to 100% CO 2 cylinder, an
additional regulator adapter must be installed
4. Connect the gun trigger connector from the gun between the regulator and cylinder valve. If
and cable to the mating receptacle inside the com- adapter is equipped with a plastic washer, be sure
partment located above the gun connection made it is seated for connection to the CO2 cylinder.
in item 3 above. Make sure that the keyways are 5. Attach one end of the inlet gas hose to the outlet
aligned, insert and tighten retaining ring. fitting of the flow regulator, the other end to the
POWER MIG 200 rear fitting, and tighten the union
SHIELDING GAS nuts securely with a wrench.
(For Gas Metal Arc Welding Processes)
6. Before opening the cylinder valve, turn the regula-
Customer must provide cylinder of appropriate type tor adjusting knob counterclockwise until the
shielding gas for the process being used. adjusting spring pressure is released.

A gas flow regulator, for Argon blend gas, and an inlet 7. Standing to one side, open the cylinder valve slow-
gas hose are factory provided with the POWER MIG ly a fraction of a turn. When the cylinder pressure
200. When using 100% CO2 an additional adapter will gauge pointer stops moving, open the valve fully.
be required to connect the regulator to the gas bottle.
WARNING
WARNING
Never stand directly in front of or behind the flow
CYLINDER may explode if regulator when opening the cylinder valve. Always
damaged. stand to one side.
• Gas under pressure is explosive. Always ___________________________________________
keep gas cylinders in an upright position
and always keep chained to undercarriage
or stationary support. See American
8. The flow regulator is adjustable. Adjust it to the
National Standard Z-49.1, “Safety in flow rate recommended for the procedure and
Welding and Cutting” published by the process being used before making the weld.
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.

POWER MIG 200

B-1 OPERATION B-1

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 contain-
ers.

ARC RAYS can burn eyes

and skin.
• Wear eye, ear and body protec-
tion.

Observe all safety information throughout

this manual.

POWER MIG 200

B-2 OPERATION B-2

PRODUCT DESCRIPTION LIMITATIONS

The output voltage/current of the POWER MIG 200 is
The POWER MIG™ 200 is a complete semiautomatic subject to vary if the input power to the machine
DC voltage arc welding machine built to meet NEMA varies, due to its tapped transformer power topology.
specifications. It combines a tapped transformer volt- In some cases an adjustment of WFS preset and/or
age power source with a constant speed wire feeder voltage tap selection may be required to accommo-
to form a reliable robust performance welding system. date a significant drift in input power.
A simple control scheme, consisting of continuous full
range wire feed speed control, and 7 output voltage DESCRIPTION OF CONTROLS
tap selections provides versatility with ease of use and
accuracy. Power ON/OFF Switch — Place the lever in the "ON"
position to energize the POWER MIG 200.
Other features include a 2" (51 mm) O.D. wire reel Voltage Control — Seven voltage tap selections are
spindle with adjustable brake, an integral gas cylinder provided Labeled "A" (minimum voltage) through "G"
mounting undercarriage, an adjustable Argon blend (maximum voltage). It should only be adjusted when
flow regulator with cylinder pressure gauge and inlet not welding. The control selection can be preset to the
hose, a 12 ft. (3.6 m) Magnum 250L GMAW gun and setting specified on the Procedure Decal on the inside
cable with fixed (flush) nozzle, a 7 ft. (2.1 m) power of the wire compartment door.
cable with plug, and a 10 ft. (3.0 m) work cable with Wire Speed Control — This controls the wire feed
clamp. speed from 50 – 700 inches per minute (1.2 – 17.8
m/min). Wire speed is not affected when changes are
Optional Spool Gun and Adapter kit, Dual Cylinder made in the voltage control.
Mounting kit and Aluminum Feeding Kit for push feed-
ing with standard built in feeder are also available.

WIRE DRIVE ROLL

RECOMMENDED PROCESSES AND The drive rolls installed with the POWER MIG each
EQUIPMENT have two grooves, both for .030-.035" (0.8-0.9 mm)
solid steel electrode. Drive roll size is indicated by the
The POWER MIG 200 is recommended for GMA stenciling on the exposed side of the drive roll. If feed-
welding processes using 10 to 44 lb (4.5 to 20 kg) 2" ing problems occur, then the drive roll may be
(51 mm) I.D. spools or Readi-Reel® coils (with option- reversed or changed. See "Procedure for Changing
al adapter) of .025" through .045" (0.6 – 1.2 mm) solid Drive Roll" in this section.
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- WIRE SIZE CONVERSION PARTS
shielding electrodes.
The POWER MIG 200 is rated to feed .025 through
The POWER MIG is factory equipped to feed .035" .045" (0.6-1.2 mm) solid or cored electrode sizes.
(0.9 mm) electrodes. It also includes a 200A, 60% The drive roll kits and Magnum 250L gun and cable
duty cycle (or 250A, 40% duty cycle) rated, 12 ft. (3.6 parts are available to feed different sizes and types of
m) GMAW gun and cable assembly equipped for electrodes. See Accessories section.
these wire sizes. Use of GMAW processes requires a
supply of shielding gas.

WELDING CAPABILITY
The POWER MIG 200 is rated at 200 amps @ 22
volts, at a 30% duty cycle based on a ten minute cycle
time. It is capable of higher duty cycles at lower output
currents. The tapped transformer design makes it
well suited for use with most portable or in-plant gen-
erating systems.

POWER MIG 200

B-3 OPERATION B-3
PROCEDURE FOR CHANGING 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.
DRIVE AND IDLE ROLL SETS
1. Turn off the power source. 7. Set one of the Readi-Reel inside cage wires on the slot in the retain-
ing spring tab.
2. Release the pressure on the idle roll by swinging
the adjustable pressure arm down toward the back 8. Lower the Readi-Reel to depress the retaining spring and align the
of the machine. Lift the cast idle roll assembly and other inside cage wires with the grooves in the molded adapter.
allow it to sit in an upright position..
9. Slide cage all the way onto the adapter until the retaining spring
3. Remove the outside wire guide retaining plate by "pops up" fully.
loosening the two large knurled screws.
CAUTION
4. Twist the drive roll retaining mechanism to the
unlocked position as shown below and remove the CHECK TO BE SURE THE RETAINING SPRING HAS FULLY
drive roll. (See Figure A.4) RETURNED TO THE LOCKING POSITION AND HAS SECURELY
LOCKED THE READI-REEL CAGE IN PLACE. RETAINING SPRING
FIGURE A.4 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.1

UNLOCKED POSITION LOCKED POSITION

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 To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300
tightening the two large knurled screws. Reposition mm Diameter) or 14Lb.(6 Kg) Innershield Coils:
the adjustable pressure arm to its original position
to apply pressure. Adjust pressure as necessary. (For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil Adapter must be
used).
WIRE REEL LOADING - READI-REELS, 1. Open the Wire Drive Compartment Door
SPOOLS OR COILS
To Mount a 30 Lb. (14 kg) Readi-Reel Package 2. Depress the Release Bar on the Retaining Collar and remove it
from the spindle.
(Using the Molded Plastic K363-P Readi-Reel
Adapter:) 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:
1. Open the Wire Drive Compartment Door 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
2. Depress the Release Bar on the Retaining Collar and remove it from reel in a direction so as to de-reel from the top of the coil.
the spindle.
4. Re-install the Retaining Collar. Make sure that the Release Bar
3. Place the Optional Adapter on the spindle “pops up” and that the collar retainers fully engage the retaining
ring groove 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 TO START THE WELDER
on the spindle. Turn the “Power Switch” switch to “ON”. This lights the red LED dis-
play lights. With the desired voltage and wire speed selected, oper-
5. Rotate the spindle and adapter so the retaining spring is at the 12
ate the gun trigger for welder output and to energize the wire feed
o'clock position.
POWER MIG 200
motor.
B-4 OPERATION B-4

FEEDING WIRE ELECTRODE

MAKING A WELD
WARNING 1. Check that the electrode polarity is correct for the
When triggering, the electrode and drive mecha- process being used, then turn the power switch
nism are electrically “hot” relative to work and ON.
ground and remain “hot” several seconds after
the gun trigger is released. 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
NOTE: Check that drive rolls, guide plates and gun Application Chart on the door inside the wire com-
parts are proper for the wire size and type being used. partment as a quick reference for some common
Refer to Table C.1 in Accessories section. welding procedures.

1. Turn the Readi-Reel or spool until the free end of 3. Press the trigger to feed the wire electrode through
the electrode is accessible. the gun and cable and then cut the electrode within
approximately 3/8" (10 mm) of the end of the con-
2. While securely holding the electrode, cut off the tact tip [3/4" (20 mm) Outershield®].
bent end and straighten the first six inches. (If the
electrode is not properly straightened, it may not 4. If welding gas is to be used, turn on the gas supply
feed properly through the wire drive system). and set the required flow rate (typically 25-35 CFH;
12-16 liters/min).
3. Release the pressure on the idle roll by swinging
the adjustable pressure arm down toward the back 5. When using Innershield electrode, the gas nozzle
of the machine. Lift the cast idle roll assembly and may be removed from the insulation on the end of
allow it to sit in an upright position. Leave the outer the gun and replaced with the gasless nozzle. This
wire guide plate installed. Manually feed the wire will give improved visibility and eliminate the possi-
through the incoming guide bushing and through bility of the gas nozzle overheating.
the guide plates (over the drive roll groove). Push a
sufficient wire length to assure that the wire has fed 6. Connect work cable to metal to be welded. Work
into the gun and cable assembly without restriction. clamp must make good electrical contact to the
Reposition the adjustable pressure arm to its origi- work. The work must also be grounded as stated in
nal position to apply pressure to the wire. “Arc Welding Safety Precautions”.

4. Press gun trigger to feed the electrode wire WARNING

through the gun.
When using an open arc process, it is necessary
IDLE ROLL PRESSURE SETTING to use correct eye, head, and body protection.
The optimum idle roll pressure varies with type of
wire, wire diameter, surface conditions, lubrication,
and hardness. As a general rule, hard wires may 7. Position electrode over joint. End of electrode
require greater pressure, and soft, or aluminum wire, may be lightly touching the work.
may require less pressure than the factory setting.
The optimum idle roll setting can be determined as 8. Lower welding helmet, close gun trigger, and
follows: begin welding. Hold the gun so the contact tip to
1. Press end of gun against a solid object that is elec- work distance is about 3/8" (10 mm) [3/4" (20
trically isolated from the welder output and press mm) for Outershield].
the gun trigger for several seconds.
2. If the wire “birdnests”, jams or breaks at the drive 9. To stop welding, release the gun trigger and then
roll, the idle roll pressure is too great. Back the pull the gun away from the work after the arc
adjustment knob out 1/2 turn, run new wire through goes out.
gun, and repeat above steps.
3. If the only result was drive roll slippage, loosen the 10. When no more welding is to be done, close valve
adjustment knob on the conductor plate and pull on gas cylinder (if used), momentarily operate
the gun cable forward about 6" (15 cm). There gun trigger to release gas pressure, and turn off
should be a slight waviness in the expose wire. If POWER MIG 200.
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. POWER MIG 200
B-5 OPERATION B-5

AVOIDING WIRE FEEDING INPUT LINE VOLTAGE VARIATIONS

PROBLEMS High Line Voltage — Higher than rated input voltage
Wire feeding problems can be avoided by observing will result in output voltages higher than normal for a
the following gun handling procedures: given tap setting. If your input line is high, you may
want to select a lower voltage tap than given on the
1. Do not kink or pull cable around sharp corners. recommended procedure chart.
2. Keep the gun cable as straight as possible when Low Line Voltage — You may not be able to get
welding or loading electrode through cable. maximum output from the machine if the line voltage
3. Do not allow dolly wheels or trucks to run over is less than rated input. The unit will continue to weld,
cables. but the output may be less than normal for a given tap
4. Keep cable clean by following maintenance setting. If your input line is low, you may want to
instructions. select a higher voltage tap than given on the recom-
5. Use only clean, rust-free electrode. The Lincoln mended procedure chart.
electrodes have proper surface lubrication.
6. Replace contact tip when the arc starts to become WIRE FEED OVERLOAD
unstable or the contact tip end is fused or PROTECTION
deformed. The POWER MIG has solid state overload protection
7. Keep wire reel spindle brake tension to minimum of the wire drive motor. If the motor becomes over-
required to prevent excess reel over-travel which loaded, the protection circuitry turns off the wire feed
may cause wire “loop-offs” from coil. speed and gas solenoid. Check for proper size tip,
8. Use proper drive rolls and wire drive idle roll pres- liner, and drive rolls, for any obstructions or bends in
sure for wire size and type being used. the gun cable, and any other factors that would
impede the wire feeding. to resume welding, simply
FAN CONTROL pull the trigger. There is no circuit breaker to reset, as
The fan is designed to come on when input power is the protection is done with reliable solid state elec-
applied to the POWER MIG 200 and go off when tronics.
power is removed.
WELDING THERMAL OVERLOAD
PROTECTION
The POWER MIG 200 has built-in protective ther-
mostats that respond to excessive temperature. They
open the wire feed and welder output circuits if the
machine exceeds the maximum safe operating tem-
perature because of a frequent overload, or high
ambient temperature plus overload. The thermostats
automatically reset when the temperature reaches a
safe operating level and welding and feeding are
allowed again, when gun is retriggered.

Steel Thickness Wire Feed Speed/Voltage Tap Settings

Wire Dia. Gas Type WireType Polarity 18 gage 16 gage 14 gage 12 gage10gage 3/16 1/4 5/16 3/8 1/2

Outershield 3/4" ESO†

.035 75Ar/25CO2 OS71M DC+ 250/D 300/E 350/F 500/G *500/G
.035 100%CO2 OS71M DC+ 300/E 350/F 500/G
.045 75Ar/25CO2 OS71M DC+ 200/E 225/F 250/G 250/G *250/G

Innershield 3/8" ESO

.035 NoneReq’d NR-211MP DC- 50/B 70/B 80/B 90/C 100/C
.045 NoneReq’d NR-211MP DC- 50/B 70/C 90/C 110/D *130/E
.045 NoneReq’d NR212 DC- 40/B 50/B 60/B 65/C 70/C 90/C 110/D *130/E *150/E *150/E
* Note- Requires Mutiple Pass .035 & .045 NR-211 MP is only
† Electrical Stickout recommended for a maximun of 5/16"

POWER MIG 200

C-1 ACCESSORIES C-1
DRIVE ROLL KITS ALTERNATIVE MAGNUM GMAW
GUN AND CABLE ASSEMBLIES
Refer to Table C.1 for various drive roll kits that are
available for the POWER MIG 200.The item in Bold is The following Magnum 250L gun and cable assem-
supplied standard with the POWER MIG 200. blies are separately available for use with the POWER
MIG 200. Each is rated 200 amps 60% duty cycle and
Wire Size Drive Roll Kit is equipped with the integrated connector, twist-lock
trigger connector, fixed nozzle and insulator, and
.023”-.030” (0.6-0.8 mm) KP1696-030S includes a liner, diffuser, and contact tips for the wire
Solid
.035” (0.9 mm) KP1696-035S sizes specified:
Steel
.045” (1.2 mm) KP1696-045S
English Wire Metric Wire
Length Part No. Size Size
Cored .035” (0.9 mm) KP1697-035C
10' (3.0 m) K533-1
.045” (1.2 mm) KP1697-045C 12' (3.6 m) K533-2 .035 – .045" 0.9 – 1.2 mm
15' (4.5 m) K533-3
Aluminum 3/64” (1.2 mm) KP1695-3/64A 10' *3.0 m) K533-4
12' (3.6 m) K533-5 .025 – .030" 0.6 – 0.8 mm
TABLE C.1 15' (4.5 m) K533-6

3/64" (1.2 mm) ALUMINUM

FEEDING KIT (K1703-1) MAGNUM GUN CONNECTION KIT
(Optional K466-6)
This kit helps push feeding aluminum through stan-
dard machine feeder and gun. It provides gun and Using the optional K466-6 Magnum Connection kit for
wire drive conversion parts to weld with 3/64" (1.2 the POWER MIG permits use of standard Magnum
mm) aluminum wire. 5356 alloy aluminum wire is rec- 200, 300 or 400 gun and cable assemblies.
ommended 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.
SPOOL GUN AND ADAPTER KIT
(K1809-1)
The K1809-1includes the Magnum 250SG Spool gun
K363P READI-REEL ADAPTER and the adapter kit for connecting the spool gun to the
Power MIG 200.
The K363P Readi-Reel Adapter mounts to the 2" spin-
dle. It is needed to mount the 22-30 lb. Readi-Reels. The Adapter Kit provides toggle switch selection
between the machine’s use with its feeder gun or the
DUAL CYLINDER MOUNTING KIT spool gun for same polarity welding with different wire
(K1702-1) and gas processes.

Permits stable side-by-side mounting of two full size The kit includes a spool gun adapter module assem-
(9" dia. x 5' high) gas cylinders with “no lift” loading. bly with a single connecting plug and trigger switch, a
Simple installation and easy instructions provided. rear gas inlet, fitting hose, solenoid valve assembly,
Includes upper and lower cylinder supports, wheel and mounting hardware with installation and operation
axles and mounting hardware. instructions.

WARNING
Remove all input power to the POWER MIG 200
before installing the Spool Gun and Kit.

POWER MIG 200

C-2 ACCESSORIES C-2
MAKING A WELD WITH THE SPOOL GUN
ADAPTER KIT AND SPOOL GUN
INSTALLED

CAUTION
In either toggle switch position, closing either gun
trigger will cause the electrode of both guns to be
electrically “HOT”. Be sure unused gun is posi-
tioned so electrode or tip will not contact metal
case or other metal common to work.

1. Setting spool gun selector switch to the “Normal”

position and pulling the trigger for the built-in feed-
er gun.

• Disables spool gun operation and spool gun

gas solenoid valve.

• Closing feeder gun trigger starts feeder gun

welding and makes both electrodes electrically
“HOT”.

2. Setting spool gun selector switch to the Spool Gun

Position and pulling SPOOL GUN Trigger.

• Disables built-in feeder gun operation and

machine gas solenoid valve.

• Enables spool gun operation and spool gun gas

solenoid valve.

• Closing spool gun trigger starts spool gun weld-

ing and makes both electrodes electrically
“HOT”.

3. Operation with POWER MIG 200:

• Turn the POWER MIG-200 input power ON.

• Adjusting the voltage tap control will increase or

decrease your welding voltage.

• Adjusting the wire speed control on the spool

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

4. Refer to the procedure decal on the Power Mig for

initial aluminum settings. Make a test weld to deter-
mine the final settings.

5. To return to normal POWER MIG 200 welding,

release the spool gun trigger set spool gun selector
switch to normal and reset feeder gun voltage pro-
cedure setting if necessary.

POWER MIG 200

D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS CONTACT TIP AND GAS NOZZLE
INSTALLATION
WARNING 1. Choose the correct size contact tip for the elec-
trode being used (wire size is stenciled on the side
ELECTRIC SHOCK can kill. of the contact tip) and screw it snugly into the gas
diffuser.
• Have an electrician install and
service this equipment.
2. Screw the appropriate fixed gas nozzle fully onto
• Turn the input power off at the the diffuser. Either the standard .50" (12.7 mm)
fuse box before working on flush nozzle or other optional flush or recessed
equipment (spray arc) nozzle sizes may be used. (See Table
• Do not touch electrically hot D.2 in this section.)
parts.
3. If using optional adjustable slip-on nozzles, see
Table D.2 in this section.
GENERAL MAINTENANCE
• Be sure the nozzle insulator is fully screwed
In extremely dusty locations, dirt may clog the air pas- onto the gun tube and does not block the gas
sages causing the welder to run hot. Blow dirt out of holes in the diffuser.
the welder with low-pressure air at regular intervals to
eliminate excessive dirt and dust build-up on internal • Slip the appropriate gas nozzle onto the nozzle
parts. insulator. Either a standard .50" (12.7 mm) or
optional .62" (15.9 mm) I.D. slip-on gas nozzle
The fan motors have sealed ball bearings which may be used and should be selected based on
require no service. the welding application.

* Adjust the gas nozzle as appropriate for the

DRIVE ROLLS AND GUIDE PLATES GMAW process to be used. Typically, the con-
tact tip end should be flush to .12" (3.2 mm)
After every coil of wire, inspect the wire drive mecha- extended for the short-circuiting transfer
nism. Clean it as necessary by blowing with low pres- process and .12" (3.2 mm) recessed for spray
sure compressed air. Do not use solvents for cleaning transfer.
the idle roll because it may wash the lubricant out of
the bearing. All drive rolls are stamped with the wire
sizes they will feed. If a wire size other than that GUN TUBES AND NOZZLES
stamped on the roll is used, the drive roll must be
changed. 1. Replace worn contact tips as required.

For instructions on replacing or changing drive roll, 2. Remove spatter from inside of gas nozzle and
see “Wire Drive Rolls” in Operation section. 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
electrode. Remove the cable from the wire feeder
and lay it out straight on the floor. Remove the con-
tact tip from the gun. Using an air hose and only par-
tial pressure, gently blow out the cable liner from the
gas diffuser end.

POWER MIG 200

D-2 MAINTENANCE D-2

CAUTION 4. Insert a new untrimmed liner into the connector

end of the cable. Be sure the liner bushing is sten-
Excessive pressure at the start may cause the dirt cilled appropriately for the wire size bing used.
to form a plug.
5. Fully seat the liner bushing into the connector.
tighten the set screw on the brass cable connector.
Flex the cable over its entire length and again blow the gas diffuser, at this time, should not be
out the cable. Repeat this procedure until no further installed onto the end of the gun tube.
dirt comes out. If this has been done and feed prob-
lems are experienced, try liner replacement, and refer 6. With the gas diffusor still removed from the gun
to trouble shooting section on rough wire feeding. tube, be sure the cable is straight, and then trim
the liner to the length shown in Figure D.1.
LINER REMOVAL AND REPLACE- Remove any burrs from the end of the liner.
MENT 7. Screw the gas diffuser onto the end of the gun tube
and securely tighten. Be sure the gas diffuser is
NOTE: Changing the liner for a different wire size
correct for the liner being used. (See table and dif-
requires replacement of the gas diffuser per Table D.1
fuser stencil.)
to properly secure the different liner.
8. Tighten the set screw in the side of the gas diffuser
against the cable liner using a 5/64" (2.0 mm) Allen
TABLE D.1 wrench.
Fixed Adjustable
Nozzle Nozzle
Replacement Size Stencilled Gas Diffuser Gas Diffuser FIGURE D.1
Diameter of Liner Part on End of Part No. Part No.
Electrodes Used Number Liner Bushing (and Stencil) (and Stencil)
SET SCREW
.025-.030" Steel M16087-2 .030 (0.8 mm) S19418-3 S19418-2
(0.6-0.8 mm) BRASS CABLE CONNECTOR
1-1/4"
(31.8mm)
.035-.045" Stee M16087-1 .045 (1.2 mm) S19418-3 S19418-1 LINER
(0.9-1.2 mm) TRIM
LENGTH
3/64" Aluminum M17714-1 3/64" (1.2 mm) S19418-3 S19418-1
(1.2 mm)
SET SCREW

LINER REMOVAL, INSTALLATION AND TRIMMING GAS DIFFUSER

INSTRUCTIONS FOR NOZZLE INSULATOR (IF USED)
MAGNUM 250L GAS NOZZLE

NOTE: The variation in cable lengths prevents the

interchangeability of liners between guns. Once a liner
has been cut for a particular gun, it should not be
installed in another gun unless it can meet the liner CAUTION
cutoff length requirement. Liners are shipped with the
This screw should only be gently tightened.
jacket of the liner extended the proper amount.
Overtightening will split or collapse the liner and
cause poor wire feeding.
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.

POWER MIG 200

D-3 MAINTENANCE D-3
GUN HANDLE DISASSEMBLY TABLE D.2
ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS
The internal parts of the gun handle may be FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES
inspected or serviced if necessary. English Metric
Description Part No. Size Size
The gun handle consists of two halves that are CABLE LINER
held together with a collar on each end. To For 15' (4.5 m) or M16087-2 .025 – .030" 0.6 – 0.8 mm
open up the handle, turn the collars approxi- shorter Cable M16087-1 .035 – .045" 0.9 – 1.2 mm
mately 60 degrees counterclockwise (the same M17714-1 3/64" 1.2 mm
(Alum. wire) (Alum. wire)
direction as removing a right hand thread) until
the collar reaches a stop. Then pull the collar CONTACT TIPS
off the gun handle. If the collars are difficult to Standard Duty S19391-6 .025" 0.6 mm
turn, position the gun handle against a corner, S19391-7 .030" 0.8 mm
S19391-1 * .035" 0.9 mm
place a screwdriver against the tab on the col-
S19391-2 .045" 1.2 mm
lar and give the screwdriver a sharp blow to Heavy Duty S19392-1 .035" 0.9 mm
turn the collar past an internal locking rib. S19292-2 .045" 1.2 mm
Tapered S19393-5 .025" 0.6 mm
S19393-6 .030" 0.8 mm
S19393-1 .035" 0.9 mm
S19393-2 .045" 1.2 mm
Tab (For Aluminum) S18697-46 3/64" 1.2 mm
(Alum. Wire) (Alum. Wire)

GAS NOZZLES
Counterclockwise Fixed (Flush) M16081-1 3/8" 9.5 mm
M16081-2 * 1/2" 12.7 mm
➣

M16081-3 5/8" 15.9 mm

Fixed (Recessed) M16080-1 3/8" 9.5 mm
M16080-2 1/2" 12.7 mm
M16080-3 5/8" 15.9 mm
Requires: Gas
Diffuser As'bly S19418-3 * .025 – .045" 0.6 – 1.2 mm

Adjustable Slip-On M16093-2 1/2" 12.7 mm

M16093-1 5/8" 15.9 mm
Requires:
Nozzle Insulator S19417-1
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

Gasless Nozzle M16938 Δ

(For Innershield)

GUN TUBE ASSEMBLIES

Standard (60°) S18920 *
45° S19890
* Included with POWER MIG 200
Δ Requires S19418-1 Gas Diffuser Assembly.

POWER MIG 200

E-1 TROUBLESHOOTING E-1

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 Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

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

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER MIG 200

E-2 TROUBLESHOOTING E-2
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical 1. Contact your Local Lincoln
Damage is Evident Authorized Field Service Facility.

There is no wire feed or open cir- 1 The gun trigger or cable may be
cuit voltage when the gun trigger is faulty. Check or replace gun
pulled. Input power is applied to assembly.
POWER MIG 200. 2. The thermal protection circuit
may be activated. If this is the
case allowing the machine to
cool will clear the error condition.
3. Make sure input voltage is cor-
rect and matches nameplate rat-
ing and reconnect panel configu-
ration.
4. If spool gun option kit is in
stalled, check to see that it is set
to “Normal” if pulling the gun trig-
ger associated with built in feed-
er, and “Spool Gun” if pulling
spool gun trigger. If all recommended possible areas
of misadjustment have been
Output voltage and wire feed is pre- 1. Remove gun assembly from checked and the problem persists,
sent when gun trigger is not pulled machine. If problem is solved Contact your local Lincoln
(not activated). gun assembly is faulty. Repair or Authorized Field Service Facility.
replace.
2. If problem persists when gun
assembly is removed from
machine then the problem is
within the POWER MIG 200.

Machine output is low. Welds are 1. Check input voltage. Make sure
“cold”, weld bead is rounded or input voltage matches name-
bumped up demonstrating poor plate rating and reconnect panel
wetting into plate. configuration.
2. Make sure settings for wire feed
speed and voltage are correct
for process being used.
3. Make sure output polarity is cor-
rect for process being used.
4. Check welding cables and gun
assembly for loose or faulty con-
nections.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
POWER MIG 200
E-3 TROUBLESHOOTING E-3
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT COURSE OF ACTION
OUTPUT PROBLEMS
1. Poor arc striking with electrode 1. Make sure settings for wire feed
sticking or blasting off. speed and voltage are correct
for process being used.
2. The gas shielding may be If all recommended possible areas
improper for process being used. of misadjustment have been
3. Check imput line voltage to be checked and the problem persists,
with in machines recommended Contact your local Lincoln
rating range. Authorized Field Service Facility.
4. Check that the machine recon-
nect panel is configured properly
for the applied voltage.

FEEDING PROBLEMS
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
1. Rough wire feeding or wire will 1. The gun cable may be kinked or twisted.
not feed but drive rolls are turn- 2. The wire may be jammed in the gun
ing. cable, or gun cable may be dirty.
3. Check drive roll tension and
position of grooves.
4. Check for worn or loose drive rolls.
5. The electrode may be rusty or dirty.
6. Check for damaged or incorrect
contact tip.
7. Check wire spindle for ease of
rotation and adjust break ten-
sion knob if necessary. If all recommended possible areas
of misadjustment have been
8. Check that the gun is pushed all checked and the problem persists,
the way into gun mount and Contact your local Lincoln
properly seated. Authorized Field Service Facility.
1. The wire feed stops while weld- 1. Check the wire feed drive rolls
ing. When trigger is released and motor for smooth operation.
and pulled again the wire feed 2. Check for restrictions in the wire
starts. feed path. Check the gun and
cable for restrictions.
3. Make sure gun liner and tip are
correct for wire size being used.
4. Make sure drive rolls and guide plates
are clean and are the correct size.
5. Check spindle for ease of rotation.

1. No control of wire feed speed. 1. The wire feed speed control may
Other machine functions are nor- be dirty. Rotate several times
mal. and check if problem is resolved.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
POWER MIG 200
E-4 TROUBLESHOOTING E-4
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
GAS FLOW PROBLEMS
Gas does not flow when gun trigger 1. Make sure gas supply is con-
is pulled. nected properly and turned “on”.

2. If the gas solenoid does actuate

(click) when the gun trigger is If all recommended possible areas
pulled there may be a restriction of misadjustment have been
in the gas supply line. checked and the problem persists,
Contact your local Lincoln
3. The gun cable assembly may be Authorized Field Service Facility.
faulty. Check or replace.

4. If gas solenoid does not operate

when gun trigger is pulled the
problem is within the POWER
MIG 200.

5. Make sure the gun is pushed all

the way into gun mount and is
properly seated.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.

POWER MIG 200

 F-1

POWER MIG 200 (208/230V)

GENERAL INFORMATION NOTES:

ELECTRICAL SYMBOLS PER E1537 N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF
IMMEDIATE AND FUTURE APPLICATIONS. CONTROL BOARD
CAVITY NUMBERING SEQUENCE COLOR CODE N.B. 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.
1 8 1 3 1 R- RED
J1 J2 J3 U- BLUE
101A 1
9 16 4 6
2 INDICATES CONNECTOR CAVITY No. 102A 2
RECTIFIER
TRANSFORMER ASSEMBLY
THERMOSTAT THERMOSTAT 103A
** CAVITY 3

104C 104B 104A 104A 4

NUMBERING SEQUENCE
(NON-LEAD SIDE OF CONNECTOR) 105A 5

J4 (TRIGGER,
106A 6
TACHOMETER,
MOTOR SIDE)
107A 7
1 3 1 4
108A 8
PA
103A J1
4 6
5 8 109A 9
R2
110A 10

109A 111A
113A 11

WIRE FEED 112A 12

SPEED
113A 13

114A 14

108A
115A 15

116A 16
106A X9 114A X10 J5
116A PA
BAFFLE

-
MOUNTED 116B 1 1
RECTIFIER
DIODE GAS
**
104C 2 2
BRIDGE SOLENOID
X10 105A
116B 3 3

+
27.8V 106C 106C 4 4
106B 107A
104D 5 5
106B
105B 6 6
X9

X8 G JUMPER PLUG
X7 F
INSTALLED FOR
H1 NON-SPOOL GUN
L1 L2 SINGLE PHASE
X6 E GUN J4 OPERATION
BRIDGE TRIGGER **
H3 H4 H2 L1 L2 X5 D RECTIFIER 1
H5 1 324 104D
TO SINGLE PHASE
SUPPLY LINE CONTACTOR 2 325 2 111A
X4 C
230V 208V H2
3 R 3 115A
H1 H4

POWER MIG 200

W X3 B 4 U 4 101A
TAP SELECTOR B 5 102A
B X2 A SWITCH
H1 6
RECONNECT H3
PANEL B 7 105B
LINE X1
G SWITCH POWER W 8 112A
S1 TRANSFORMER
TO GROUND PER
NATIONAL ELECTRICAL 1
CODE
2
3
J2
WIRING DIAGRAMS

4
B
5
+ 6

P.M. MOTOR/
GEARBOX
H1B H5 R T -
A
U C
B H
FAN
TO
MOTOR W WORK
1
FOR SPOOL GUN OPTION

J3
2

40 OHMS
R1

C1 AND C2 C1 C2
31,000 MFD 50 W
50V + +

OUTPUT
CHOKE

10- 2000

L11424
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-1
F-2 DIMENSION PRINT F-2

M19231
3-00F

POWER MIG 200

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The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
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The book contains the latest information and application
“hands on”
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and For details write: Lincoln Welding School
draftsmen use the “short-cut” language of symbols to pass 22801 St. Clair Ave.
on assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.

Practical exercises and examples develop the reader’s ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
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Lincoln Welding School Titles: Price Code Quantity Cost

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Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH
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 ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION ● Aislese del trabajo y de la tierra.

French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.

German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha-
ATENÇÃO da.
dos. corpo.

● Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer
remover fumo da zona respiratória. serviço.
moventes.
● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
 • World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com