SVM157-A October 2001 View Safety Info Return to Master TOC RETURN TO MAIN MENU POWER MIG™ 200 For use with machines having Code Numbers: 10564 10584 Return to Master TOC View Safety Info 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.
Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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 Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
Return to Master TOC Return to Master TOC ii ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
Return to Master TOC iii WELDING SPARKS can 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. 6.b.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS - INSTALLATION SECTION - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Specifications . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . Uncrating the Power MIG 200 . . . . . . . . . . . . . . . Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Power, Grounding and Connection Diagrams Dual Voltage Machine Input Connections . . . . . . .
Return to Master TOC Return to Section TOC A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS – POWER MIG 200 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency 208/230/60 Hz Input Current @ 150 Amp Rated Output Input Current @ 150 Amp Rated Output 28/26 Amps 36/33 RATED OUTPUT Duty Cycle 30% 40% 60% Amps 200 Amps 180 Amps 150 Amps Volts at Rated Amperes 22 Volts 23 Volts 24 Volts Return to Master TOC Return to Section TOC OUTPUT Welding Current Range 30 – 200 Amps Maximum Open Circuit Voltage 40
Return to Master TOC Return to Section TOC A-3 Read entire installation section before starting installation. INPUT POWER, GROUNDING AND CONNECTION DIAGRAMS SAFETY PRECAUTIONS WARNING WARNING ELECTRIC SHOCK can kill. ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Only qualified personnel should perform this installation.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC A-4 INSTALLATION A-4 FIGURE A.1 — Dual Voltage Machine Input Connections 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. 4. Using the instructions in Figure A.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC A-5 INSTALLATION FIGURE A.2 — Triple Voltage Machine Input Connections OUTPUT POLARITY CONNECTIONS FIGURE A.3 — Receptacle Diagram CONNECT TO A SYSTEM GROUNDING WIRE. SEE THE UNITED STATES NATIONAL ELECTRICAL CODE AND/OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUNDING. The welder, as shipped from the factory, is connected for electrode positive (+) polarity.
Return to Master TOC Return to Section TOC A-6 A-6 INSTALLATION 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. 2. Remove the cylinder cap.
TABLE OF CONTENTS - OPERATION SECTION - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Description . . . . . . . . . . . . . . . . . . . . . . Recommended Processes and Equipment . . . . . Welding Capability . . . . . . . . . . . . . . . . . . . . . . . Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Controls . . . . . . . . . . . . . . . . . . . . Wire Drive Roll . . .
Return to Master TOC Return to Section TOC B-2 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. Return to Master TOC • Always gloves. Return to Section TOC B-2 OPERATION wear dry insulating FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-3 B-3 OPERATION LIMITATIONS PRODUCT DESCRIPTION The POWER MIG™ 200 is a complete semiautomatic DC voltage arc welding machine built to meet NEMA specifications. It combines a tapped transformer voltage power source with a constant speed wire feeder to form a reliable robust performance welding system.
Return to Master TOC Return to Section TOC B-4 7. Set one of the Readi-Reel inside cage wires on the slot in the retaining spring tab. 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.
Return to Master TOC Return to Section TOC B-5 FEEDING WIRE ELECTRODE MAKING A WELD WARNING When triggering, the electrode and drive mechanism are electrically “hot” relative to work and ground and remain “hot” several seconds after the gun trigger is released. 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-6 B-6 OPERATION AVOIDING WIRE FEEDING PROBLEMS INPUT LINE VOLTAGE VARIATIONS Wire feeding problems can be avoided by observing the following gun handling procedures: 1. Do not kink or pull cable around sharp corners. 2. 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.
TABLE OF CONTENTS - ACCESSORIES SECTION - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 3/64” (1.2mm) Aluminum Feeding Kit (K1703-1) . . . . . . . . . . . . . . . C-2 K363P Readi-Reel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Dual Cylinder Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC C-2 C-2 ACCESSORIES 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. Wire Size Drive Roll Kit Solid Steel .023”-.030” (0.6-0.8 mm) .035” (0.9 mm) .045” (1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC C-3 ACCESSORIES MAKING A WELD WITH THE SPOOL GUN ADAPTER KIT AND SPOOL GUN INSTALLED 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 procedure setting if necessary.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC C-4 NOTES POWER MIG 200 C-4
Section D TABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . General Maintenance . . . . . . . . . . . . . . . . . . . . Drive Rolls and Guide Plates . . . . . . . . . . . . . . Contact Tip and Gas Nozzle Installation . . . . . . Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . Gun Cable Cleaning . . . . . . . . . . . . . . . . . . . . . Liner Removal and Replacement . . . .
Return to Master TOC Return to Section TOC D-2 MAINTENANCE SAFETY PRECAUTIONS CONTACT TIP AND GAS NOZZLE INSTALLATION 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 Return to Master TOC Return to Section TOC • Do not touch electrically hot parts. Return to Master TOC 2. Screw the appropriate fixed gas nozzle fully onto the diffuser. Either the standard .50" (12.
Return to Master TOC Return to Section 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.
Return to Master TOC GUN HANDLE DISASSEMBLY The internal parts of the gun handle may be inspected or serviced if necessary. TABLE D.2 ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES Description The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counterclockwise (the same direction as removing a right hand thread) until the collar reaches a stop.
Return to Master TOC Return to Section TOC D-5 D-5 MAINTENANCE 1. Case Front Assembly 2. Rear Panel Assembly 3. Center Assembly 4. Wire Drive Assembly 5. Base & Power Component Assembly 6 Return to Master TOC Return to Section TOC 6.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC D-6 NOTES POWER MIG 200 D-6
TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . Voltage Selector Switch . . . . . . . . . . . . . . . . . . . Baffle Mounted Diode Bridge . . . . . . . . . . . . . . . Control Circuits . . . . . . . . . . . . . . . . . . . . . . . .
E-2 THEORY OF OPERATION FIGURE E.2 – INPUT POWER CIRCUIT.
E-3 THEORY OF OPERATION FIGURE E.3 – CONTROL CIRCUITS.
E-4 THEORY OF OPERATION FIGURE E.4 – OPTIONAL CIRCUITS.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC E-5 THEORY OF OPERATION E-5 PROTECTIVE DEVICES AND CIRCUITS THERMAL AND OVERLOAD PROTECTION WIREFEED OVERLOAD PROTECTION The POWER MIG 200 has two built-in protective thermostats that respond to excessive temperatures. One is located on the main transformer.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC E-6 NOTES POWER MIG 200 E-6
Return to Master TOC Return to Master TOC Section F TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . How to Use Troubleshooting Guide . . . . . . . . . . . . . PC Board Troubleshooting Procedures . . . . . . . . . . . Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Transformer Test . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Section TOC F-2 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.
Return to Master TOC Return to Section 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. Return to Master TOC Return to Section TOC Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-4 TROUBLESHOOTING AND REPAIR Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) F-4 Observe Safety Guidelines detailed in the beginning of this manual.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-5 TROUBLESHOOTING AND REPAIR Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) F-5 Observe Safety Guidelines detailed in the beginning of this manual.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-6 TROUBLESHOOTING AND REPAIR Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) Observe Safety Guidelines detailed in the beginning of this manual.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-7 TROUBLESHOOTING AND REPAIR Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) F-7 Observe Safety Guidelines detailed in the beginning of this manual.
Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING AND REPAIR Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) F-8 Observe Safety Guidelines detailed in the beginning of this manual. RECOMMENDED COURSE OF ACTION WIRE FEEDING PROBLEMS 1. The gun cable may be kinked or Rough wire feeding or the wire will twisted. not feed but the drive rolls are turning.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-9 TROUBLESHOOTING AND REPAIR Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) F-9 Observe Safety Guidelines detailed in the beginning of this manual.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-10 TROUBLESHOOTING AND REPAIR Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) F-10 Observe Safety Guidelines detailed in the beginning of this manual.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-12 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) FIGURE F.1. – OUTPUT SELECTOR SWITCH TERMINALS X2 X3 X4 X5 X6 X7 X8 6. Locate leads X9 and X10. See Figure F.3. TEST PROCEDURE Return to Master TOC Return to Section TOC WARNING THE ON/OFF POWER SWITCH will be “hot” during these tests. NOTE: Secondary voltages will vary proportionately with the primary input voltage. 7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) FIGURE F.2. – LEAD X1 X1 X9 X10 FIGURE F.3.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-14 TABLE F.1. Test Points INPUT VOLTAGE TEST POINTS EXPECTED VOLTAGE READING 230 VAC X1-X2 11.9-13.0 VAC 230 VAC X1-X3 14.1-15.2 VAC 230 VAC X1-X4 16.2-17.5 VAC 230 VAC X1-X5 18.4-19.7 VAC 230 VAC X1-X6 20.5-22.0 VAC 230 VAC X1-X7 22.7-24.2 VAC 230 VAC X1-X8 24.8-26.5 VAC 230 VAC X9-X10 26.9-28.8 VAC 12.
Return to Master TOC Return to Section TOC F-15 TROUBLESHOOTING AND REPAIR 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 precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-16 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) FIGURE F.4. – PLUG J4 Black Tach Black Arm White Arm J11 Blue Tach Red Tach Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. 2. Open the side panels and remove the tool tray using a 5/16” nutdriver.
Return to Master TOC Return to Section TOC F-17 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) 5. Make the following voltage tests: 2. Locate plug J4. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • All input power must be electrically disconnected before proceeding. 3. Locate the tach leads on plug J4. See Figure F.5. 4. Connect the main input power to the machine. 5.
Return to Master TOC Return to Section TOC F-18 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) TEST FOR FEEDBACK VOLTAGE TO CONTROL BOARD FROM LEAD TO LEAD EXPECTED VOLTAGE 2. Locate plug J4 and the tach leads. See Figure F.5. Black (-) BLUE (+) 3.0 TO 4.0 VDC Return to Master TOC 4. Make the following voltage tests: Return to Section TOC c. Turn the machine ON and pull the gun trigger to conduct the voltage test. 1. Disconnect the main AC input power to the machine. 3.
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-20 OUTPUT BRIDGE RECTIFIER TEST (continued) TEST PROCEDURE 1. Remove input power to the POWER MIG 200 machine. 2. Using the 3/8” nutdriver, remove the left case side. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 3. 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.
Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING AND REPAIR 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 Master TOC Return to Section 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. Return to Master TOC Return to Section TOC 3. Locate and remove leads 106B, 106C and 107A from the contactor coil terminals. See Figure F.7. See the Wiring Diagram. 4. Using the 7/16” wrench, remove one lead from the contactors large terminals. See Figure F.7.
Return to Master TOC Return to Section TOC F-23 F-23 TROUBLESHOOTING AND REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) Return to Master TOC Return to Section TOC 0 Volts Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 10.0 V 5 ms MACHINE LOADED TO 200 AMPS AT 22 VDC SCOPE SETTINGS This is a typical DC output voltage waveform generated from a properly operat- Volts/Div.................................10V/Div ing machine.
Return to Master TOC Return to Section TOC F-24 F-24 TROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”) Return to Master TOC Return to Section TOC 0 Volts 20.0 V 1.0 ms Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC SCOPE SETTINGS This is a typical DC output voltage waveform generated from a properly operat- Volts/Div.................................20V/Div ing machine.
Return to Master TOC TROUBLESHOOTING AND REPAIR 0 Volts Return to Master TOC Return to Master TOC Return to Section TOC 20.0 V Return to Section TOC F-25 ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) ONE OUTPUT DIODE NOT FUNCTIONING Return to Master TOC Return to Section TOC Return to Section TOC F-25 5 ms MACHINE LOADED TO 180 AMPS AT 16 VDC SCOPE SETTINGS This is NOT a typical DC output voltage waveform. One output diode is not functioning.
Return to Master TOC Return to Section TOC F-26 F-26 TROUBLESHOOTING AND REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”) Return to Master TOC Return to Section TOC 0 Volts Return to Master TOC Return to Section TOC 20.0 V 5 ms SCOPE SETTINGS This is NOT a typical DC output voltage waveform. The output capacitors are not functioning. Note the lack of “filtering” in the output waveform. The output capacitor bank was disconnected.
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-28 TROUBLESHOOTING AND REPAIR CONTROL BOARD REPLACEMENT (continued) PROCEDURE 1. Remove power to the machine. 6. Carefully remove the control board. 2. Using a 5/16” nutdriver, remove the three screws securing the tool tray. 7. Mount the new board to the nylon mounting pins. 3. Locate the control board. 8.
Return to Master TOC Return to Section TOC F-29 TROUBLESHOOTING AND REPAIR WIRE DRIVE 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-30 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued) FIGURE F.9. - WIRE DRIVE LOCATION Wire Drive PROCEDURE 5. Using a 5/16” nutdriver, remove the three mounting screws next to the wire drive assembly. See Figure F.10. Return to Master TOC Return to Section TOC 1. Remove power to the machine. 2. Lift cover to gain access to the wire drive. See Figure F.9. 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-31 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued) FIGURE F.10. - WIRE DRIVE HOSE & LEAD LOCATION 5/16" Sheet Metal Screws 9/16" Bolt Gas Hose 5/16" Monuting Screws FIGURE F.11.
Return to Master TOC Return to Section TOC F-32 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued) 1. Place the new wire drive assembly into its proper position. 5. Using a 3/4” nut driver, replace the thick black lead previously removed. 2. Connect plug J4. 6. Reconnect the gas hose to the wire drive assembly. 3. Maneuver assembly back into its original position. 7. Close case wrap around cover.
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-34 TROUBLESHOOTING AND REPAIR OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) PROCEDURE 1. Using a 3/8” nutdriver, remove the left side of the case wraparound cover. 2. Locate the output diode bridge rectifier. Figure F.12. See 7. Using a 1/2” nutdriver remove the three bolts mounting the bracket to the rectifier. The rectifier is now ready for repair or replacement. See Figure F.13. 8.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-35 TROUBLESHOOTING AND REPAIR F-35 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) FIGURE F.13.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-36 NOTES POWER MIG 200 F-36
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-38 TROUBLESHOOTING AND REPAIR OUTPUT CAPACITORS REPLACEMENT (Continued) 5. Remove the capacitor bank assembly from the machine. PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side case wraparound cover. See Figure F.14. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC 4. Using a 3/8” nutdriver, remove the three capacitor bank nuts and lock washers from the three mounting bolts. See Figure F.15.
Return to Master TOC Return to Section TOC F-39 TROUBLESHOOTING AND REPAIR F-39 OUTPUT CAPACITORS REPLACEMENT (Continued) FIGURE F.15.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-40 NOTES POWER MIG 200 F-40
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-42 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove both sides of the case wraparound cover. 7. Using a 1/2” nutdriver, label and remove lead X1 from the output diode bridge rectifier. 2. Using a 5/16” nutdriver, remove the tool tray. 8. Using a 5/16” Nutdriver, open the rear access panel. See Figure F.20. 3. Locate the main transformer. F.16.
Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT (Continued) 15. Carefully maneuver the main transformer out the left side of the machine. 5. Reconnect lead X1 to the output diode bridge rectifier. NOTE: Two people may be needed to maneuver the main transformer out of the machine. 6. Reconnect leads X8, X7, X6, X5, X4, X3, & X2 previously removed from the switch assembly. REPLACEMENT 7.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-44 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT (Continued) FIGURE F.18. - LEADS SWITCH LEADS X2 X3 X4 X5 X6 X7 X8 t n o Fr + Return to Master TOC Return to Section TOC 121 118 FIGURE F.19.
Return to Master TOC Return to Section TOC F-45 F-45 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT (Continued) FIGURE F.20. - REAR ACCESS PANEL Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 5/16" Nut REAR ACCESS PANEL Lead 118 4 230V 208V L1 L2 FIGURE F.21.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-46 NOTES POWER MIG 200 F-46
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC F-48 FAN BLADE/MOTOR REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side of the case wraparound cover. 8. Replace the fan motor and fan blade if necessary. 2. Perform the Output Capacitor Bank Removal Procedure. 9. Tighten the fan blade mounting band. Return to Master TOC 3. Using a 5/16” nutdriver, remove the four fan mounting screws from the rear of the machine. See Figure F.22.
Return to Master TOC Return to Section TOC 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 detailed throughout this manual.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-50 F-50 TROUBLESHOOTING AND REPAIR OUTPUT CONTACTOR REPLACEMENT (Continued) PROCEDURE 7. Replace output contactor. 1. Using a 5/16” nutdriver, remove the three screws securing the tool tray. 2. Locate the output contactor. F.23. See Figure 8. Using a 7/16” wrench, mount the new output contactor in its proper location. 9. Reconnect leads 106B, 106C, & 107A to their proper terminals. See Wiring Diagram. 3.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING AND REPAIR OUTPUT CONTACTOR REPLACEMENT (Continued) FIGURE F.24.
Return to Master TOC Return to Section TOC F-52 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts/Herts Maximum Idle Amps Maximum Idle Watts 230/60 2.0 150 OPEN CIRCUIT VOLTAGE Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 35 - 40 VDC Return to Section TOC F-52 TROUBLESHOOTING AND REPAIR WIRE SPEED RANGE 50 - 700 IPM (1.27 - 17.
TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTIONELECTRICAL DIAGRAMS . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . CONTROL PC BOARD SCHEMATIC . CONTROL PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-2 ELECTRICAL DIAGRAMS WIRING DIAGRAM - 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. N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIVE”. TO CHANGE POLARITY, TURN THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK STUD. CAVITY NUMBERING SEQUENCE COLOR CODE BWRU- (COMPONENT SIDE OF P.C.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC G-3 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
R124 R105 C2 R1 D5 R5 T1 TP 3 D4 R3 X2 R128 R126 TP 4 C1 DZ1 R4 R19 R129 Q1 C3 C9 Q9 TP 6 D3 DZ7 R9 D11 TP 1 C5 C17 D7 D8 D13 TP 7 C19 R40 R7 R21 R82 X5 C18 R85 C8 R127 R23 D6 C4R12 R38 R15 C6 C7 Q3 R43 C16 R36 R35 R20 R39 Q2 R18 R53 R84 R107 D1 R2 TP 2 C48 R30 R28 R33 R16 R17 R68 Q5 R52 C30 DZ4 R31 R8 R56 R55 D14 R80 C32 C26 R81 D10 X1 DZ9 C15 R6 C25 R58 R34 R48 R37 C10 R22 D12 R10 D2 R46 R45 R47 R61 R27 C13 X4 C14 TP 9 X6 R41 C35
Return to Master TOC 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 column 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. Clair Ave.