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Lincoln Electric Power MIG 215 User Manual

Lincoln Electric Power MIG 215
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POWER MIG
215
OPERATOR’S MANUAL
IM828-A
April, 2007
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.
For use with machine Code Numbers
11070,
1
11099,
1
11247
For use with machine Code Numbers
• 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
• World's Leader in Welding and Cutting Products •
Copyright © 2007 Lincoln Global Inc.
R
C
UL
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Lincoln Electric Power MIG 215 Specifications

General IconGeneral
Input PhaseSingle Phase
Output Current Range (MIG)30 - 215 A
Output Current Range (Stick)20 - 160 A
Duty Cycle (Stick at 160 A)30%
Rated Output215 A
Welding ProcessMIG, Stick, Flux-Cored
Wire Feed Speed Range50 - 500 IPM
Wire Diameter Range (MIG)0.023-0.045 in
Electrode Diameter Range (Stick)1/16-5/32 in
Weight38 lb (17.2 kg)

Summary

Safety Overview

Importance of Safety

Introduces the importance of safety in using the equipment.

Operational Safety Warnings

California Proposition 65 Compliance

Specific warnings regarding California Proposition 65.

Engine Safety Precautions

Safety guidelines for engine-powered equipment operation.

Electric & Magnetic Field Hazards

Risks associated with EMF fields during welding.

Welding Hazard Warnings

Electrical Shock Hazards

Dangers of electric shock during welding operations.

Arc Ray Hazards and Protection

Risks from arc rays and required eye/skin protection.

Fumes & Gases Safety

Dangers of inhaling welding fumes and gases.

Process Safety Concerns

Fire & Explosion Risks

Risks from welding sparks and flammable materials.

Compressed Gas Cylinder Safety

Dangers associated with compressed gas cylinders.

Electrical Equipment Safety

Safety guidelines for electrically powered equipment.

Installation and Specifications

Technical Specifications

Detailed technical data for the POWER MIG 215.

Installation Procedures

Installation Safety Precautions

Safety guidelines specific to the installation process.

Uncrating and Placement

Procedures for unpacking and positioning the welder.

Power Connection and Grounding

How to connect the welder to the power supply.

Electrical Connections

Input Power Configuration

Visual guide for connecting the input power.

Setting Output Polarity

How to set electrode polarity.

Welding System Setup

Gun & Cable Installation

Connecting the welding gun and cable.

Shielding Gas Connection

Instructions for connecting the shielding gas supply.

Auxiliary Power Outlets

Information on available power outlets.

Operational Safety Practices

Electric Shock Prevention

Preventing electric shock during operation.

Fume & Gas Control

Managing fumes and gases during operation.

Spark & Explosion Prevention

Preventing fires and explosions from sparks.

Eye & Skin Protection

Protecting eyes and skin from arc rays.

Product Overview and Controls

Product Description & Features

Overview of the POWER MIG 215 features.

Machine Limitations

Factors affecting machine performance and output.

Control Panel Functions

Explanation of the machine's controls and their functions.

Wire Drive System

Details on drive rolls and parts for wire size changes.

Wire Handling and Setup

Changing Drive & Idle Rolls

Step-by-step guide for replacing drive rolls.

Loading Wire Reels & Coils

Instructions for loading wire reels and coils.

Initiating Welding Operation

How to power on and initiate welding.

Wire Feeding Mechanics

Wire Feeding Procedure

Step-by-step process for feeding the welding wire.

Idle Roll Pressure Adjustment

How to adjust idle roll pressure for optimal performance.

Wire Drive Configuration

Adjusting the wire drive for different wire types.

Welding Execution

Performing a Weld

Step-by-step guide to performing a weld.

Operational Performance & Protection

Input Voltage Impact

How input voltage affects output and settings.

Overload Protection Systems

Explanation of wire feed and thermal overload protection.

Recommended Procedure Settings

Recommended settings for various welding scenarios.

Available Accessories

Drive Roll Kits

Various drive roll kits for different wire types.

Alternative Gun Assemblies

Different Magnum gun and cable options.

Gun Connection Kits

Kits for connecting different guns and adapters.

Spool Gun Welding

Spool Gun Operation Guide

How to weld using the spool gun adapter and spool gun.

Maintenance Essentials

Maintenance Safety

Safety guidelines specific to maintenance tasks.

General Cleaning & Care

Routine cleaning and inspection of the welder.

Drive Roll & Guide Plate Care

Maintaining drive rolls and guide plates.

Tip & Nozzle Maintenance

Procedures for maintaining contact tips and nozzles.

Gun Cable Cleaning

How to clean the gun cable liner to prevent feeding issues.

Gun Liner Maintenance

Liner Removal & Replacement

Step-by-step guide for replacing the gun liner.

Gun Handle Servicing

Gun Handle Disassembly

How to take apart the gun handle for inspection or service.

Troubleshooting Guide

Using the Guide

Instructions on how to effectively use the troubleshooting section.

Troubleshooting Output Issues

Major Damage or No Output

Diagnosing major damage or complete lack of output.

Wire Feed Present, No Output

Troubleshooting when wire feeds but no welding output occurs.

Low Output or Poor Weld Quality

Diagnosing low output and poor weld quality.

Troubleshooting Arc & Feed Issues

Poor Arc Quality

Resolving issues with poor arc striking or electrode behavior.

Auxiliary Receptacle Failure

Troubleshooting a non-functional auxiliary power outlet.

Rough Wire Feeding

Resolving issues with rough or stalled wire feeding.

Troubleshooting Feed & Gas

Intermittent Wire Feed Stop

Diagnosing wire feed stops and restarts.

Wire Speed Control Issues

Troubleshooting loss of wire feed speed control.

Gas Flow Problems

Diagnosing issues with shielding gas flow.

Electrical Diagrams

Wiring Diagram - Code 11070

Electrical schematic for specific model code 11070.

Electrical Diagrams (Continued)

Wiring Diagram - Codes 11099+

Electrical schematic for models with codes 11099 and above.

Physical Dimensions

Unit Dimensions & Measurements

Visual representation of the unit's physical dimensions.

Critical Safety Reminders

Essential Safety Instructions

Key safety instructions for safe operation.

Operational Safety Alerts

Servicing & Operation Precautions

Crucial safety reminders for operation and servicing.

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