Lincoln Electric Welder SVM157 A User Manual
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SVM157-A  
October 2001  
™
POWER MIG 200  
For use with machines having Code Numbers:  
10564  
10584  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be  
increased by proper installation  
... and thoughtful operation on  
your part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED THROUGHOUT. And,  
most importantly, think before you  
act and be careful.  
SERVICE 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  
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ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free gloves  
to insulate hands.  
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. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases.When welding, keep  
• AC Welder with Reduced Voltage Control.  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition.  
Replace damaged insulation.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
phosgene, a highly toxic gas, and other irritating  
products.  
form  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage of  
both welders.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
3.j. Also see Items 6.c. and 8.  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.e. Also see item 1.b.  
Mar ‘95  
POWER MIG 200  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use  
only compressed gas cylinders  
containing the correct shielding gas for the  
process used and properly operating  
regulators designed for the gas and  
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.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
• Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
• A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
(see address above).  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing through lift-  
ing chains, crane cables or other alternate circuits. This can cre-  
ate fire hazards or overheat lifting chains or cables until they fail.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
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  
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iv  
iv  
SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
7. Quand on ne soude pas, poser la pince à une endroit isolé de la  
masse. Un court-circuit accidental peut provoquer un échauffe-  
ment et un risque d’incendie.  
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:  
8. S’assurer que la masse est connectée le plus prés possible de la  
zone de travail qu’il est pratique de le faire. Si on place la masse  
sur la charpente de la construction ou d’autres endroits éloignés  
de la zone de travail, on augmente le risque de voir passer le  
courant de soudage par les chaines de levage, câbles de grue, ou  
autres circuits. Cela peut provoquer des risques d’incendie ou  
d’echauffement des chaines et des câbles jusqu’à ce qu’ils se  
rompent.  
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. Eviter toujours tout con-  
tact entre les parties sous tension et la peau nue ou les véte-  
ments mouillés. Porter des gants secs et sans trous pour isol-  
er les mains.  
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci  
est particuliérement important pour le soudage de tôles gal-  
vanisées plombées, ou cadmiées ou tout autre métal qui produit  
des fumeés toxiques.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans l e s  
positions assis ou couché pour lesquelles une grande partie  
du corps peut être en contact avec la masse.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La chaleur  
ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant  
pour produire du phosgéne (gas fortement toxique) ou autres pro-  
duits irritants.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension des  
porte-électrodes connectés à deux machines à souder parce  
que la tension entre les deux pinces peut être le total de la ten-  
sion à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le  
code “Code for safety in welding and cutting” CSA Standard W  
117.2-1974.  
f. Si on utilise la machine à souder comme une source de courant  
pour soudage semi-automatique, ces precautions pour le  
porte-électrode s’applicuent aussi au pistolet de soudage.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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 du  
corps.  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:  
a. Utiliser un bon masque avec un verre filtrant approprié ainsi  
qu’un verre blanc afin de se protéger les yeux du rayonnement  
de l’arc et des projections quand on soude ou quand on  
regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif de  
montage ou la piece à souder doit être branché à une bonne mise  
à la terre.  
b. Porter des vêtements convenables afin de protéger la peau de  
soudeur et des aides contre le rayonnement de l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au soudage à  
l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la debrancher à  
l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de soudage.  
Se protéger avec des vêtements de protection libres de l’huile, tels  
que les gants en cuir, chemise épaisse, pantalons sans revers, et  
chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur place.  
5. Toujours porter des lunettes de sécurité dans la zone de soudage.  
Utiliser des lunettes avec écrans lateraux dans les zones où l’on  
pique le laitier.  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
Mar. ‘93  
POWER MIG 200  
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v
v
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
Page  
i-iv  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D  
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E  
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F  
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G  
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P372 & P202-H.2  
POWER MIG 200  
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Section A  
Section A  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A  
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Uncrating the Power MIG 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Input Power, Grounding and Connection Diagrams . . . . . . . . . . . . . . . .  
Dual Voltage Machine Input Connections . . . . . . . . . . . . . . . . . . . . . . .  
Triple Voltage Machine Input Connections . . . . . . . . . . . . . . . . . . . . . .  
Output Polarity Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun and Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
A-2  
A-3  
A-3  
A-3  
A-3  
A-4  
A-5  
A-5  
A-6  
A-6  
POWER MIG 200  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS – POWER MIG 200  
INPUT – SINGLE PHASE ONLY  
Standard Voltage/Frequency  
Input Current @ 150 Amp Rated Output Input Current @ 150 Amp Rated Output  
208/230/60 Hz  
28/26 Amps  
36/33  
RATED OUTPUT  
Duty Cycle  
30%  
Amps  
Volts at Rated Amperes  
22 Volts  
200 Amps  
180 Amps  
150 Amps  
40%  
60%  
23 Volts  
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  
Rating On  
in Conduit  
AWG (IEC) Sizes  
(For lengths  
in Conduit  
AWG (IEC) Sizes  
(For lengths  
Input Voltage/  
Fuse or Breaker  
Size (Super Lag)  
Frequency (Hz)  
Nameplate  
up to 100 ft.)  
exceeding 100 ft.)  
2
2
208/60  
230/60  
60  
60  
36  
33  
10 (6 mm )  
8 (10 mm )  
2
2
10 (6 mm )  
8 (10 mm )  
NOTE: Use #10 AWG Grounding Wire  
PHYSICAL DIMENSIONS  
Height  
Width  
Depth  
Weight  
31.79 in  
808 mm  
18.88 in  
480 mm  
38.78 in  
985 mm  
210 Ibs  
95 kg  
WIRE SPEED RANGE  
Wire Speed  
50 – 700 IPM (1.27 – 17.8 m/minute)  
POWER MIG 200  
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A-3  
A-3  
INSTALLATION  
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.  
• All input power must be electrically dis-  
connected before proceeding.  
• Only personnel that have read and under-  
stood the POWER MIG 200 Operating  
Manual should install and operate this  
equipment.  
1. Before starting the installation, check with the local  
power company if there is any question about  
whether your power supply is adequate for the volt-  
age, amperes, phase, and frequency specified on  
the welder nameplate. Also be sure the planned  
installation will meet the U.S. National Electrical  
Code and local code requirements. This welder may  
be operated from a single phase line or from one  
phase of a two or three phase line.  
• Machine must be grounded per any  
national, local or other applicable electri-  
cal codes.  
• The POWER MIG power switch is to be in  
the OFF position when installing work  
cable and gun and when connecting other  
equipment.  
UNCRATING THE POWER MIG 200  
2. Models that have multiple input voltages specified  
on the nameplate (e.g. 208/230) are shipped con-  
nected for the highest voltage. If the welder is to be  
operated on lower voltage, it must be reconnected  
according to the instructions in Figure A.1 for dual  
voltage machines and Figure A.2 for triple voltage  
machines.  
Cut banding and lift off cardboard carton. Cut banding  
holding the machine to the skid. Remove foam and  
corrugated packing material. Untape accessories from  
Gas Bottle Platform. Unscrew the two wood screws (at  
the Gas Bottle Platform) holding the machine to the  
skid. Roll the machine off the skid assembly.  
WARNING  
LOCATION  
Make certain that the input power is electrically  
disconnected before removing the screw on the  
reconnect panel access cover.  
Locate the welder in a dry location where there is free  
circulation of clean air into the louvers in the back and  
out the front. A location that minimizes the amount of  
smoke and dirt drawn into the rear louvers reduces the  
chance of dirt accumulation that can block air pas-  
sages and cause overheating.  
POWER MIG 200  
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A-4  
A-4  
INSTALLATION  
FIGURE A.1 — Dual Voltage Machine Input Connections  
4. Using the instructions in Figure A.3, have a quali-  
fied electrician connect a receptacle (Customer  
Supplied) or cable to the input power lines and the  
system ground per the U.S. National Electrical  
Code and any applicable local codes. See  
“Technical Specifications” at the beginning of this  
chapter for proper wire sizes. For long runs over  
100 feet, larger copper wires should be used. Fuse  
the two hot lines with super lag type fuses as shown  
in the following diagram. The center contact in the  
receptacle is for the grounding connection. A green  
wire in the input cable connects this contact to the  
frame of the welder. This ensures proper grounding  
of the welder frame when the welder plug is insert-  
ed into a grounded receptacle.  
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.  
POWER MIG 200  
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A-5  
A-5  
INSTALLATION  
FIGURE A.2 — Triple Voltage Machine Input Connections  
OUTPUT POLARITY CONNECTIONS  
FIGURE A.3 — Receptacle Diagram  
The welder, as shipped from the factory, is connected  
for electrode positive (+) polarity. This is the normal  
polarity for GMA welding.  
CONNECT TO A SYSTEM  
GROUNDING WIRE. SEE  
THE UNITED STATES  
NATIONAL ELECTRICAL  
CODE AND/OR LOCAL  
CODES FOR OTHER  
If negative (–) polarity is required, interchange the con-  
nection of the two cables located in the wire drive com-  
partment near the front panel. The electrode cable,  
which is attached to the wire drive, is to be connected  
to the negative (–) labeled terminal and the work lead,  
which is attached to the work clamp, is to be connect-  
ed to the positive (+) labeled terminal.  
DETAILS AND MEANS FOR  
PROPER GROUNDING.  
CONNECT TO HOT WIRES  
OF A THREE-WIRE, SINGLE  
PHASE SYSTEM OR TO ONE  
PHASE OF A TWO OR  
THREE PHASE SYSTEM.  
POWER MIG 200  
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A-6  
A-6  
INSTALLATION  
2. Remove the cylinder cap. Inspect the cylinder  
valves and regulator for damaged threads, dirt,  
dust, oil or grease. Remove dust and dirt with a  
clean cloth.  
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.  
DO NOT ATTACH THE REGULATOR IF OIL,  
GREASE OR DAMAGE IS PRESENT! Inform your  
gas supplier of this condition. Oil or grease in the  
presence of high pressure oxygen is explosive.  
WARNING  
3. Stand to one side away from the outlet and open the  
cylinder valve for an instant. This blows away any  
dust or dirt which may have accumulated in the  
valve outlet.  
Turn the welder power switch off before installing  
gun and cable.  
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  
longer protrudes into gun opening as seen from  
front of machine.  
Be sure to keep your face away from the valve out-  
let when “cracking” the valve.  
3. Insert the male end of gun cable into the female  
casting through opening in front panel. Make sure  
connector is fully inserted and tighten knurled  
screw.  
4. Attach the flow regulator to the cylinder valve and  
tighten the union nut(s) securely with a wrench.  
NOTE: If connecting to 100% CO cylinder, an  
2
additional regulator adapter must be installed  
between the regulator and cylinder valve. If adapter  
is equipped with a plastic washer, be sure it is seat-  
4. Connect the gun trigger connector from the gun and  
cable to the mating receptacle inside the compart-  
ment located above the gun connection made in  
item 3 above. Make sure that the keyways are  
aligned, insert and tighten retaining ring.  
ed for connection to the CO cylinder.  
2
5. Attach one end of the inlet gas hose to the outlet fit-  
ting of the flow regulator, the other end to the  
POWER MIG 200 rear fitting, and tighten the union  
nuts securely with a wrench.  
SHIELDING GAS  
(For Gas Metal Arc Welding Processes)  
Customer must provide cylinder of appropriate type  
shielding gas for the process being used.  
6. Before opening the cylinder valve, turn the regulator  
adjusting knob counterclockwise until the adjusting  
spring pressure is released.  
A gas flow regulator, for Argon blend gas, and an inlet  
gas hose are factory provided with the POWER MIG  
7. Standing to one side, open the cylinder valve slow-  
ly a fraction of a turn. When the cylinder pressure  
gauge pointer stops moving, open the valve fully.  
200. When using 100% CO an additional adapter will  
2
be required to connect the regulator to the gas bottle.  
WARNING  
WARNING  
CYLINDER may explode if  
damaged.  
Never stand directly in front of or behind the flow  
regulator when opening the cylinder valve. Always  
stand to one side.  
___________________________________________  
8. The flow regulator is adjustable. Adjust it to the flow  
rate recommended for the procedure and process  
being used before making the weld.  
• Gas under pressure is explosive. Always  
keep gas cylinders in an upright position  
and always keep chained to undercarriage  
or stationary support. See American  
National Standard Z-49.1, “Safety in  
Welding and Cutting” published by the  
American Welding Society.  
Install shielding gas supply as follows:  
1. Set gas cylinder on rear platform of POWER MIG  
200. Hook chain in place to secure cylinder to rear  
of welder.  
POWER MIG 200  
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Section B  
Section B  
TABLE OF CONTENTS  
- OPERATION SECTION -  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B  
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . .  
Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Description of Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Size Conversion Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Procedure for Changing Drive and Idle Roll Sets . . . . . . . . . . . . . . . . .  
Wire Reel Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
To Start the Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Feeding Wire Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Idle Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Input Line Voltage Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wirefeed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Welding Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . .  
B-2  
B-3  
B-3  
B-3  
B-3  
B-3  
B-3  
B-3  
B-4  
B-4  
B-4  
B-5  
B-5  
B-5  
B-6  
B-6  
B-6  
B-6  
B-6  
POWER MIG 200  
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B-2  
B-2  
OPERATION  
Read entire Operation section before  
operating the POWER MIG 200.  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts  
or electrode with skin or wet  
clothing. Insulate yourself from  
work and ground.  
• Always wear dry insulating  
gloves.  
FUMES AND GASES can be  
dangerous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
WELDING  
SPARKS  
can  
cause fire or explosion.  
• Keep flammable material away.  
• Do not weld on closed containers.  
ARC RAYS can burn eyes and  
skin.  
• Wear eye, ear and body protec-  
tion.  
Observe all safety information throughout  
this manual.  
POWER MIG 200  
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B-3  
B-3  
OPERATION  
PRODUCT DESCRIPTION  
LIMITATIONS  
The output voltage/current of the POWER MIG 200 is  
subject to vary if the input power to the machine varies,  
due to its tapped transformer power topology. In some  
cases an adjustment of WFS preset and/or voltage tap  
selection may be required to accommodate a signifi-  
cant drift in input power.  
The POWER MIG™ 200 is a complete semiautomatic  
DC voltage arc welding machine built to meet NEMA  
specifications. It combines a tapped transformer volt-  
age power source with a constant speed wire feeder to  
form a reliable robust performance welding system. A  
simple control scheme, consisting of continuous full  
range wire feed speed control, and 7 output voltage tap  
selections provides versatility with ease of use and  
accuracy.  
DESCRIPTION OF CONTROLS  
Power ON/OFF Switch — Place the lever in the "ON"  
position to energize the POWER MIG 200. See Figure  
B.1.  
Other features include a 2" (51 mm) O.D. wire reel  
spindle with adjustable brake, an integral gas cylinder  
mounting undercarriage, an adjustable Argon blend  
flow regulator with cylinder pressure gauge and inlet  
hose, a 12 ft. (3.6 m) Magnum 250L GMAW gun and  
cable with fixed (flush) nozzle, a 7 ft. (2.1 m) power  
cable with plug, and a 10 ft. (3.0 m) work cable with  
clamp.  
Voltage Control — Seven voltage tap selections are  
provided Labeled "A" (minimum voltage) through "G"  
(maximum voltage). It should only be adjusted when  
not welding. The control selection can be preset to the  
setting specified on the Procedure Decal on the inside  
of the wire compartment door. See Figure B.?.  
Wire Speed Control — This controls the wire feed  
speed from 50 – 700 inches per minute (1.2 – 17.8  
m/min). Wire speed is not affected when changes are  
made in the voltage control. See Figure B.1.  
Optional Spool Gun and Adapter kit, Dual Cylinder  
Mounting kit and Aluminum Feeding Kit for push feed-  
ing with standard built in feeder are also available.  
Figure B.1. Control Locations  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
The POWER MIG 200 is recommended for GMA weld-  
ing processes using 10 to 44 lb (4.5 to 20 kg) 2" (51  
mm) I.D. spools or Readi-Reel coils (with optional  
WIRE FEED SPEED  
VOLTAGE  
®
ON/OFF SWITCH  
adapter) of .025" through .045" (0.6 – 1.2 mm) solid  
steel, .035" (0.9 mm) stainless, 3/64" (1.2 mm) alu-  
O
N
O
F
F
®
minum and .045" (1.2 mm) Outershield ; as well as  
®
.035" (0.9 mm) and .045" (1.2 mm) Innershield self-  
shielding electrodes.  
The POWER MIG is factory equipped to feed .035"  
(0.9 mm) electrodes. It also includes a 200A, 60% duty  
cycle (or 250A, 40% duty cycle) rated, 12 ft. (3.6 m)  
GMAW gun and cable assembly equipped for these  
wire sizes. Use of GMAW processes requires a supply  
of shielding gas.  
WIRE DRIVE ROLL  
The drive rolls installed with the POWER MIG each  
have two grooves, both for .030-.035" (0.8-0.9 mm)  
solid steel electrode. Drive roll size is indicated by the  
stenciling on the exposed side of the drive roll. If feed-  
ing problems occur, then the drive roll may be reversed  
or changed. See "Procedure for Changing Drive  
Roll" in this section.  
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 cur-  
rents. The tapped transformer design makes it well  
suited for use with most portable or in-plant generating  
systems.  
WIRE SIZE CONVERSION PARTS  
The POWER MIG 200 is rated to feed .025 through  
.045" (0.6-1.2 mm) solid or cored electrode sizes.  
The drive roll kits and Magnum 250L gun and cable  
parts are available to feed different sizes and types of  
electrodes. See Accessories section.  
POWER MIG 200  
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B-4  
B-4  
OPERATION  
7. Set one of the Readi-Reel inside cage wires on the slot in the retain-  
ing spring tab.  
PROCEDURE FOR CHANGING  
DRIVE AND IDLE ROLL SETS  
8. Lower the Readi-Reel to depress the retaining spring and align the  
other inside cage wires with the grooves in the molded adapter.  
9. Slide cage all the way onto the adapter until the retaining spring "pops  
up" fully.  
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..  
CAUTION  
CHECK TO BE SURE THE RETAINING SPRING HAS FULLY  
RETURNED TO THE LOCKING POSITION AND HAS SECURELY  
LOCKED THE READI-REEL CAGE IN PLACE. RETAINING SPRING  
MUST REST ON THE CAGE, NOT THE WELDING ELECTRODE.  
-----------------------------------------------------------------------------------------------  
10. To remove Readi-Reel from Adapter, depress retaining spring tab  
with thumb while pulling the Readi-Reel cage from the molded  
adapter with both hands. Do not remove adapter from spindle.  
3. Remove the outside wire guide retaining plate by  
loosening the two large knurled screws.  
4. Wiggle both the metal idle and drive rolls off of their  
plastic hubs.  
5. Remove the inside wire guide plate.  
FIGURE B.2  
6. Replace the drive and idle rolls and inside wire  
guide with a set marked for the new wire size.  
NOTE: Be sure that the gun liner and contact tip are  
also sized to match the selected wire size.  
7. Manually feed the wire from the wire reel, over the  
drive roll groove and through the wire guide and  
then into the brass bushing of the gun and cable  
assembly.  
8. Replace the outside wire guide retaining plate by  
tightening the two large knurled screws. Reposition  
the adjustable pressure arm to its original position  
to apply pressure. Adjust pressure as necessary.  
To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300 mm  
Diameter) or 14Lb.(6 Kg) Innershield Coils:  
WIRE REEL LOADING - READI-REELS,  
SPOOLS OR COILS  
(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil Adapter must be  
used).  
To Mount a 30 Lb. (14 kg) Readi-Reel Package  
(Using the Molded Plastic K363-P Readi-Reel  
Adapter:)  
1. Open the Wire Drive Compartment Door  
2. Depress the Release Bar on the Retaining Collar and remove it  
from the spindle.  
1. Open the Wire Drive Compartment Door.  
3. Place the spool on the spindle making certain the spindle brake  
pin enters one of the holes in the back side of the spool (Note: an  
arrow mark on the spindle lines up with the brake holding pin to  
assist in lining up a hole). Be certain the wire comes off the reel  
in a direction so as to de-reel from the top of the coil.  
2. Depress the Release Bar on the Retaining Collar and remove it from  
the spindle.  
3. Place the Optional Adapter on the spindle  
4. Re-install the Retaining Collar. Make sure that the Release Bar “pops  
up” and that the collar retainers fully engage the retaining ring groove  
on the spindle.  
4. Re-install the Retaining Collar. Make sure that the Release Bar  
“pops up” and that the collar retainers fully engage the retaining  
ring groove on the spindle.  
5. Rotate the spindle and adapter so the retaining spring is at the 12  
o'clock position.  
TO START THE WELDER  
Turn the “Power Switch” switch to “ON”. This lights the red LED dis-  
play lights. With the desired voltage and wire speed selected, oper-  
ate the gun trigger for welder output and to energize the wire feed  
motor.  
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.  
POWER MIG 200  
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B-5  
B-5  
OPERATION  
FEEDING WIRE ELECTRODE  
WARNING  
MAKING A WELD  
1. Check that the electrode polarity is correct for the  
process being used, then turn the power switch  
ON.  
When triggering, the electrode and drive mecha-  
nism are electrically “hot” relative to work and  
ground and remain “hot” several seconds after the  
gun trigger is released.  
2. Set desired arc voltage tap and wire speed for the  
particular electrode wire, material type and thick-  
ness, and gas (for GMAW) being used. Use the  
Application Chart on the door inside the wire com-  
partment as a quick reference for some common  
welding procedures.  
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.  
3. Press the trigger to feed the wire electrode through  
the gun and cable and then cut the electrode within  
approximately 3/8" (10 mm) of the end of the con-  
1. Turn the Readi-Reel or spool until the free end of the  
electrode is accessible.  
®
tact tip [3/4" (20 mm) Outershield ].  
2. While securely holding the electrode, cut off the bent  
end and straighten the first six inches. (If the elec-  
trode is not properly straightened, it may not feed  
properly through the wire drive system).  
4. If welding gas is to be used, turn on the gas supply  
and set the required flow rate (typically 25-35 CFH;  
12-16 liters/min).  
3. Release the pressure on the idle roll by swinging the  
adjustable pressure arm down toward the back of  
the machine. Lift the cast idle roll assembly and  
allow it to sit in an upright position. Leave the outer  
wire guide plate installed. Manually feed the wire  
through the incoming guide bushing and through the  
guide plates (over the drive roll groove). Push a suf-  
ficient wire length to assure that the wire has fed into  
the gun and cable assembly without restriction.  
Reposition the adjustable pressure arm to its origi-  
nal position to apply pressure to the wire.  
5. When using Innershield electrode, the gas nozzle  
may be removed from the insulation on the end of  
the gun and replaced with the gasless nozzle. This  
will give improved visibility and eliminate the possi-  
bility of the gas nozzle overheating.  
6. Connect work cable to metal to be welded. Work  
clamp must make good electrical contact to the  
work. The work must also be grounded as stated in  
“Arc Welding Safety Precautions”.  
4. Press gun trigger to feed the electrode wire through  
the gun.  
WARNING  
When using an open arc process, it is necessary  
to use correct eye, head, and body protection.  
IDLE ROLL PRESSURE SETTING  
The optimum idle roll pressure varies with type of wire,  
wire diameter, surface conditions, lubrication, and  
hardness. As a general rule, hard wires may require  
greater pressure, and soft, or aluminum wire, may  
require less pressure than the factory setting. The opti-  
mum idle roll setting can be determined as follows:  
1. Press end of gun against a solid object that is elec-  
trically isolated from the welder output and press the  
gun trigger for several seconds.  
7. Position electrode over joint. End of electrode may  
be lightly touching the work.  
8. Lower welding helmet, close gun trigger, and begin  
welding. Hold the gun so the contact tip to work  
distance is about 3/8" (10 mm) [3/4" (20 mm) for  
Outershield].  
2. If the wire “birdnests”, jams or breaks at the drive  
roll, the idle roll pressure is too great. Back the  
adjustment knob out 1/2 turn, run new wire through  
gun, and repeat above steps.  
9. To stop welding, release the gun trigger and then  
pull the gun away from the work after the arc goes  
out.  
3. If the only result was drive roll slippage, loosen the  
adjustment knob on the conductor plate and pull the  
gun cable forward about 6" (15 cm). There should  
be a slight waviness in the expose wire. If there is  
not waviness, the pressure is too low. Tighten the  
adjustment knob 1/4 turn, reinstall the gun cable and  
repeat the above steps.  
10. When no more welding is to be done, close valve  
on gas cylinder (if used), momentarily operate gun  
trigger to release gas pressure, and turn off  
POWER MIG 200.  
POWER MIG 200  
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B-6  
B-6  
OPERATION  
AVOIDING WIRE FEEDING  
INPUT LINE VOLTAGE VARIATIONS  
PROBLEMS  
High Line Voltage — Higher than rated input voltage  
will result in output voltages higher than normal for a  
given tap setting. If your input line is high, you may  
want to select a lower voltage tap than given on the  
recommended procedure chart.  
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.  
Low Line Voltage — You may not be able to get max-  
imum output from the machine if the line voltage is less  
than rated input. The unit will continue to weld, but the  
output may be less than normal for a given tap setting.  
If your input line is low, you may want to select a high-  
er voltage tap than given on the recommended proce-  
dure chart.  
4. Keep cable clean by following maintenance instruc-  
tions.  
5. Use only clean, rust-free electrode. The Lincoln  
electrodes have proper surface lubrication.  
6. Replace contact tip when the arc starts to become  
unstable or the contact tip end is fused or deformed.  
7. Keep wire reel spindle brake tension to minimum  
required to prevent excess reel over-travel which  
may cause wire “loop-offs” from coil.  
WIRE FEED OVERLOAD  
PROTECTION  
The POWER MIG has solid state overload protection  
of the wire drive motor. If the motor becomes over-  
loaded, the protection circuitry turns off the wire feed  
speed and gas solenoid. Check for proper size tip,  
liner, and drive rolls, for any obstructions or bends in  
the gun cable, and any other factors that would impede  
the wire feeding. to resume welding, simply pull the  
trigger. There is no circuit breaker to reset, as the pro-  
tection is done with reliable solid state electronics.  
8. Use proper drive rolls and wire drive idle roll pres-  
sure for wire size and type being used.  
FAN CONTROL  
The fan is designed to come on when input power is  
applied to the POWER MIG 200 and go off when  
power is removed.  
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 ambi-  
ent temperature plus overload. The thermostats auto-  
matically reset when the temperature reaches a safe  
operating level and welding and feeding are allowed  
again, when gun is retriggered.  
TABLE B.1.  
Steel Thickness Wire Feed Speed/Voltage Tap Settings  
Wire Dia. Gas Type WireType Polarity 18 gage16 gage 14 gage 12 gage 10gage 3/16 1/4 5/16 3/8 1/2  
†
Outershield 3/4" ESO  
.035  
.035  
.045  
75Ar/25CO OS71M  
DC+  
DC+  
DC+  
250/D 300/E 350/F 500/G *500/G  
300/E 350/F 500/G  
2
100%CO  
OS71M  
2
75Ar/25CO OS71M  
200/E 225/F 250/G 250/G *250/G  
2
†
Innershield 3/8" ESO  
.035  
.045  
.045  
NoneReq’d NR-211MP  
NoneReq’d NR-211MP  
NoneReq’d NR212  
DC-  
DC-  
DC-  
50/B  
40/B  
70/B  
50/B  
80/B  
60/B  
90/C  
50/B  
65/C  
100/C  
70/C  
70/C  
90/C 110/D *130/E  
90/C 110/D *130/E *150/E *150/E  
* Note- Requires Multiple Pass  
.035 & .045 NR-211 MP is only  
†
Electrical Stickout  
recommended for a maximum of 5/16"  
POWER MIG 200  
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Section C  
Section C  
TABLE OF CONTENTS  
- ACCESSORIES SECTION -  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C  
Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3/64” (1.2mm) Aluminum Feeding Kit (K1703-1) . . . . . . . . . . . . . . .  
K363P Readi-Reel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Dual Cylinder Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Alternative Magnum GMAW Gun and Cable Assemblies . . . . . . . .  
Magnum Gun Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Spool Gun and Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Making a Weld (with the Spool Gun Adapter Kit) . . . . . . . . . . . . . . . . . .  
C-2  
C-2  
C-2  
C-2  
C-2  
C-2  
C-2  
C-3  
POWER MIG 200  
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C-2  
C-2  
ACCESSORIES  
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  
supplied standard with the POWER MIG 200.  
The following Magnum 250L gun and cable assemblies  
are separately available for use with the POWER MIG  
200. Each is rated 200 amps 60% duty cycle and is  
equipped with the integrated connector, twist-lock trig-  
ger connector, fixed nozzle and insulator, and includes  
a liner, diffuser, and contact tips for the wire sizes spec-  
ified:  
Wire  
Size  
Drive Roll Kit  
.023”-.030” (0.6-0.8 mm)  
.035” (0.9 mm)  
KP1696-030S  
KP1696-035S  
KP1696-045S  
Solid  
Steel  
English Wire  
Size  
Metric Wire  
Size  
.045” (1.2 mm)  
Length  
Part No.  
10' (3.0 m)  
12' (3.6 m)  
15' (4.5 m)  
K533-1  
K533-2  
K533-3  
.035” (0.9 mm)  
.045” (1.2 mm)  
KP1697-035C  
KP1697-045C  
Cored  
.035 – .045"  
0.9 – 1.2 mm  
10' *3.0 m)  
12' (3.6 m)  
15' (4.5 m)  
K533-4  
K533-5  
K533-6  
Aluminum  
3/64” (1.2 mm)  
KP1695-3/64A  
.025 – .030"  
0.6 – 0.8 mm  
TABLE C.1  
TABLE C.2  
3/64" (1.2 mm) ALUMINUM  
FEEDING KIT (K1703-1)  
MAGNUM GUN CONNECTION KIT  
(Optional K466-6)  
This kit helps push feeding aluminum through standard  
machine feeder and gun. It provides gun and wire drive  
conversion parts to weld with 3/64" (1.2 mm) aluminum  
wire. 5356 alloy aluminum wire is recommended for  
best push feeding performance.  
Using the optional K466-6 Magnum Connection kit for  
the POWER MIG permits use of standard Magnum  
200, 300 or 400 gun and cable assemblies.  
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  
and the adapter kit for connecting the spool gun to the  
Power MIG 200.  
K363P READI-REEL ADAPTER  
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  
spool gun for same polarity welding with different wire  
and gas processes.  
DUAL CYLINDER MOUNTING KIT  
(K1702-1)  
Permits stable side-by-side mounting of two full size  
(9" dia. x 5' high) gas cylinders with “no lift” loading.  
Simple installation and easy instructions provided.  
Includes upper and lower cylinder supports, wheel  
axles and mounting hardware.  
The kit includes a spool gun adapter module assembly  
with a single connecting plug and trigger switch, a rear  
gas inlet, fitting hose, solenoid valve assembly, and  
mounting hardware with installation and operation  
instructions.  
WARNING  
Remove all input power to the POWER MIG 200  
before installing the Spool Gun and Kit.  
POWER MIG 200  
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C-3  
C-3  
ACCESSORIES  
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.  
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 feeder  
gun.  
•
•
Disables spool gun operation and spool gun gas  
solenoid valve.  
Closing feeder gun trigger starts feeder gun  
welding and makes both electrodes electrically  
“HOT”.  
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.  
POWER MIG 200  
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C-4  
C-4  
NOTES  
POWER MIG 200  
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Section D  
Section D  
TABLE OF CONTENTS  
- MAINTENANCE SECTION -  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D  
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Gun Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Accessories and replacement parts for Magnum  
D-2  
D-2  
D-2  
D-2  
D-2  
D-2  
D-3  
D-4  
250L Gun & Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
D-4  
D-5  
POWER MIG 200  
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D-2  
D-2  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
CONTACT TIP AND GAS NOZZLE  
INSTALLATION  
1. Choose the correct size contact tip for the electrode  
being used (wire size is stenciled on the side of the  
contact tip) and screw it snugly into the gas diffuser.  
ELECTRIC SHOCK can kill.  
• Have an electrician install and  
service this equipment.  
2. Screw the appropriate fixed gas nozzle fully onto  
the diffuser. Either the standard .50" (12.7 mm)  
flush nozzle or other optional flush or recessed  
(spray arc) nozzle sizes may be used. (See Table  
D.2 in this section.)  
• Turn the input power off at the  
fuse box before working on  
equipment  
• Do not touch electrically hot  
parts.  
3. If using optional adjustable slip-on nozzles, see  
Table D.2 in this section.  
(READ THE SAFETY PRECAUTIONS IN  
THE FRONT OF THIS MANUAL BEFORE  
WORKING ON THIS MACHINE.)  
•
•
Be sure the nozzle insulator is fully screwed onto  
the gun tube and does not block the gas holes in  
the diffuser.  
GENERAL MAINTENANCE  
Slip the appropriate gas nozzle onto the nozzle  
insulator. Either a standard .50" (12.7 mm) or  
optional .62" (15.9 mm) I.D. slip-on gas nozzle  
may be used and should be selected based on  
the welding application.  
In extremely dusty locations, dirt may clog the air pas-  
sages causing the welder to run hot. Blow dirt out of  
the welder with low-pressure air at regular intervals to  
eliminate excessive dirt and dust build-up on internal  
parts.  
* Adjust the gas nozzle as appropriate for the  
GMAW process to be used. Typically, the con-  
tact tip end should be flush to .12" (3.2 mm)  
extended for the short-circuiting transfer process  
and .12" (3.2 mm) recessed for spray transfer.  
The fan motors have sealed ball bearings which  
require no service.  
DRIVE ROLLS AND GUIDE PLATES  
GUN TUBES AND NOZZLES  
After every coil of wire, inspect the wire drive mecha-  
nism. Clean it as necessary by blowing with low pres-  
sure compressed air. Do not use solvents for cleaning  
the idle roll because it may wash the lubricant out of  
the bearing. All drive rolls are stamped with the wire  
sizes they will feed. If a wire size other than that  
stamped on the roll is used, the drive roll must be  
changed.  
1. Replace worn contact tips as required.  
2. Remove spatter from inside of gas nozzle and from  
tip after each 10 minutes of arc time or as required.  
GUN CABLE CLEANING  
To help prevent feeding problems, clean cable liner  
after using approximately 300 pounds (136 kg) of elec-  
trode. Remove the cable from the wire feeder and lay  
it out straight on the floor. Remove the contact tip from  
the gun. Using an air hose and only partial pressure,  
gently blow out the cable liner from the gas diffuser  
end.  
For instructions on replacing or changing drive roll, see  
“Wire Drive Rolls” in Operation section.  
POWER MIG 200  
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D-3  
D-3  
MAINTENANCE  
4. Insert a new untrimmed liner into the connector end  
of the cable. Be sure the liner bushing is stencilled  
appropriately for the wire size bing used.  
CAUTION  
Excessive pressure at the start may cause the dirt  
to form a plug.  
5. Fully seat the liner bushing into the connector. tight-  
en the set screw on the brass cable connector. the  
gas diffuser, at this time, should not be installed  
onto the end of the gun tube.  
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.  
6. With the gas diffuser still removed from the gun  
tube, be sure the cable is straight, and then trim the  
liner to the length shown in Figure D.1. Remove any  
burrs from the end of the liner.  
LINER REMOVAL AND REPLACE-  
MENT  
7. Screw the gas diffuser onto the end of the gun tube  
and securely tighten. Be sure the gas diffuser is cor-  
rect for the liner being used. (See table and diffuser  
stencil.)  
NOTE: Changing the liner for a different wire size  
requires replacement of the gas diffuser per Table D.1  
to properly secure the different liner.  
TABLE D.1  
Fixed  
Nozzle  
Adjustable  
Nozzle  
Replacement Size Stencilled Gas Diffuser Gas Diffuser  
Diameter of  
Electrodes Used  
Liner Part  
Number  
on End of  
Part No.  
Part No.  
Liner Bushing (and Stencil) (and Stencil)  
.025-.030" Steel  
(0.6-0.8 mm)  
M16087-2  
M16087-1  
M17714-1  
.030 (0.8 mm)  
.045 (1.2 mm)  
3/64" (1.2 mm)  
S19418-3  
S19418-3  
S19418-3  
S19418-2  
S19418-1  
S19418-1  
.035-.045" Steel  
(0.9-1.2 mm)  
3/64" Aluminum  
(1.2 mm)  
8. Tighten the set screw in the side of the gas diffuser  
against the cable liner using a 5/64" (2.0 mm) Allen  
wrench.  
LINER REMOVAL, INSTALLATION AND TRIMMING  
INSTRUCTIONS FOR  
MAGNUM 250L  
FIGURE D.1  
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 cut-  
off length requirement. Liners are shipped with the  
jacket of the liner extended the proper amount.  
SET SCREW  
BRASS CABLE CONNECTOR  
1-1/4"  
(31.8mm)  
LINER  
TRIM  
LENGTH  
SET SCREW  
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.  
GAS DIFFUSER  
NOZZLE INSULATOR (IF USED)  
GAS NOZZLE  
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.  
CAUTION  
This screw should only be gently tightened.  
Overtightening will split or collapse the liner and  
cause poor wire feeding.  
POWER MIG 200  
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D-4  
D-4  
MAINTENANCE  
TABLE D.2  
GUN HANDLE DISASSEMBLY  
ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS  
FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES  
The internal parts of the gun handle may be  
inspected or serviced if necessary.  
English  
Size  
Metric  
Size  
Description  
Part No.  
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. Then pull the collar off the gun  
handle. If the collars are difficult to turn, position  
the gun handle against a corner, place a screw-  
driver against the tab on the collar and give the  
screwdriver a sharp blow to turn the collar past  
an internal locking rib.  
CABLE LINER  
For 15' (4.5 m) or  
shorter Cable  
M16087-2  
M16087-1  
M17714-1  
.025 – .030"  
.035 – .045"  
3/64"  
0.6 – 0.8 mm  
0.9 – 1.2 mm  
1.2 mm  
(Alum. wire)  
(Alum. wire)  
CONTACT TIPS  
Standard Duty  
S19391-6  
S19391-7  
.025"  
.030"  
.035"  
.045"  
.035"  
.045"  
.025"  
.030"  
.035"  
.045"  
0.6 mm  
0.8 mm  
S19391-1  
S19391-2  
S19392-1  
S19292-2  
S19393-5  
S19393-6  
S19393-1  
S19393-2  
*
0.9 mm  
1.2 mm  
0.9 mm  
1.2 mm  
0.6 mm  
0.8 mm  
0.9 mm  
1.2 mm  
1.2 mm  
(Alum. Wire)  
Heavy Duty  
Tapered  
Tab (For Aluminum) S18697-46  
3/64"  
(Alum. Wire)  
GAS NOZZLES  
Fixed (Flush)  
M16081-1  
3/8"  
1/2"  
5/8"  
3/8"  
1/2"  
5/8"  
9.5 mm  
12.7 mm  
15.9 mm  
9.5 mm  
12.7 mm  
15.9 mm  
M16081-2 *  
M16081-3  
M16080-1  
M16080-2  
M16080-3  
Fixed (Recessed)  
Counterclockwise  
Requires: Gas  
Diffuser As'bly  
S19418-3 *  
.025 – .045"  
0.6 – 1.2 mm  
Adjustable Slip-On  
Requires:  
M16093-2  
M16093-1  
1/2"  
5/8"  
12.7 mm  
15.9 mm  
Nozzle Insulator S19417-1  
As’bly  
Requires:  
Gas Diffuser  
As’bly  
S19418-2  
S19418-1  
.025 – .030"  
.035 – .045"  
0.6 – 0.8 mm  
0.9 – 1.2 mm  
Gasless Nozzle  
(For Innershield)  
M16938  
∆
GUN TUBE ASSEMBLIES  
Standard (60°)  
45°  
S18920  
S19890  
*
*
Included with POWER MIG 200  
∆ Requires S19418-1 Gas Diffuser Assembly.  
POWER MIG 200  
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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
6. Covers Assembly  
2
3
4
1
5
POWER MIG 200  
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D-6  
D-6  
NOTES  
POWER MIG 200  
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Section E  
Section E  
TABLE OF CONTENTS  
- THEORY OF OPERATION SECTION -  
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E  
Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Voltage Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Baffle Mounted Diode Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Output Rectification, Contactor & Control Boards . . . . . . . . . . . . . .  
Optional Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Control Board, Gun Trigger, & Wire Drive Motor . . . . . . . . . . . . . . .  
Protective Devices & Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wirefeed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
E-2  
E-2  
E-2  
E-2  
E-2  
E-3  
E-3  
E-4  
E-4  
E-5  
E-5  
E-5  
FIGURE E.1 THEORY OF OPERATION BLOCK DIAGRAM  
WIRE  
GAS  
SPEED  
SOLENOID  
CONTROL  
WIRE  
DRIVE  
MOTOR  
CONTROL BOARD  
FAN  
MOTOR  
RECTIFIER  
DIODE  
BRIDGE  
TRANSFORMER  
THERMOSTAT  
OUTPUT BRIDGE  
THERMOSTAT  
TACH  
FEEDBACK  
GUN TRIGGER  
LINE  
SWITCH  
TAP SELECTOR  
SWITCH  
GUN  
ASSEMBLY  
OUTPUT DIODE  
BRIDGE  
+
+
OUTPUT  
CHOKE  
POSITIVE  
TERMINAL  
OUTPUT  
CAPACITORS  
CONTACTOR  
-
-
RECONNECT  
PANEL  
MAIN  
TRANSFORMER  
NEGATIVE  
TERMINAL  
POWER MIG 200  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 – INPUT POWER CIRCUIT.  
WIRE  
GAS  
SPEED  
SOLENOID  
CONTROL  
WIRE  
DRIVE  
MOTOR  
CONTROL BOARD  
FAN  
MOTOR  
RECTIFIER  
DIODE  
BRIDGE  
TRANSFORMER  
THERMOSTAT  
OUTPUT BRIDGE  
THERMOSTAT  
TACH  
FEEDBACK  
GUN TRIGGER  
LINE  
SWITCH  
TAP SELECTOR  
SWITCH  
GUN  
ASSEMBLY  
OUTPUT DIODE  
BRIDGE  
+
+
OUTPUT  
CHOKE  
POSITIVE  
TERMINAL  
OUTPUT  
CAPACITORS  
CONTACTOR  
-
-
RECONNECT  
PANEL  
MAIN  
TRANSFORMER  
NEGATIVE  
TERMINAL  
from a minimum setting (A) to a maximum  
voltage setting (G). In addition, the main  
transformer houses a 28VAC winding. This  
28VAC is rectified at the baffle mounted diode  
bridge and the resultant DC voltage is used to  
power the electronics on the control board, the  
output contactor, and the gas solenoid.  
INPUT LINE VOLTAGE, MAIN  
TRANSFORMER, VOLTAGE  
SELECTOR SWITCH AND  
BAFFLE MOUNTED DIODE  
BRIDGE  
The single phase input power is connected to  
the POWER MIG 200 through a line switch  
located on the front panel.  
A reconnect panel allows the user to configure  
the machine for the desired input voltage. The  
AC input voltage is applied to the primary of the  
main transformer. The cooling fan motor  
(120VAC) is powered from a portion of the  
primary winding. For welding purposes, the  
main transformer converts the high voltage, low  
current input power to a lower voltage, higher  
current output. This tapped secondary winding  
is coupled to a voltage selector switch. By  
selecting one of seven positions on the switch  
the user can preset the desired voltage output  
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.  
POWER MIG 200  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 – CONTROL CIRCUITS.  
WIRE  
GAS  
SPEED  
SOLENOID  
CONTROL  
WIRE  
DRIVE  
MOTOR  
CONTROL BOARD  
FAN  
MOTOR  
RECTIFIER  
DIODE  
BRIDGE  
TRANSFORMER  
THERMOSTAT  
OUTPUT BRIDGE  
THERMOSTAT  
TACH  
FEEDBACK  
GUN TRIGGER  
LINE  
SWITCH  
TAP SELECTOR  
SWITCH  
GUN  
ASSEMBLY  
OUTPUT DIODE  
BRIDGE  
+
+
OUTPUT  
CHOKE  
POSITIVE  
TERMINAL  
OUTPUT  
CAPACITORS  
CONTACTOR  
-
-
RECONNECT  
PANEL  
MAIN  
TRANSFORMER  
NEGATIVE  
TERMINAL  
OUTPUT RECTIFICATION,  
CONTACTOR AND CONTROL  
BOARD  
The AC voltage developed on the secondary  
winding is applied, through the selector switch  
and output contactor, to the output rectifier  
bridge. This DC welding voltage is filtered by  
the output capacitors and applied to the output  
terminals and welding gun. Since the output  
choke is in series with the positive leg of the  
output rectifier and also in series with the gun  
and welding load, a filtered constant voltage  
output is applied to the output terminals of the  
machine.  
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.  
POWER MIG 200  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.4 – OPTIONAL CIRCUITS.  
WIRE  
GAS  
SPEED  
SOLENOID  
CONTROL  
WIRE  
DRIVE  
MOTOR  
CONTROL BOARD  
FAN  
MOTOR  
RECTIFIER  
DIODE  
BRIDGE  
TRANSFORMER  
THERMOSTAT  
OUTPUT BRIDGE  
THERMOSTAT  
TACH  
FEEDBACK  
GUN TRIGGER  
LINE  
SWITCH  
TAP SELECTOR  
SWITCH  
GUN  
ASSEMBLY  
OUTPUT DIODE  
BRIDGE  
+
+
OUTPUT  
CHOKE  
POSITIVE  
TERMINAL  
OUTPUT  
CAPACITORS  
CONTACTOR  
-
-
RECONNECT  
PANEL  
MAIN  
TRANSFORMER  
NEGATIVE  
TERMINAL  
CONTROL BOARD, GUN  
TRIGGER AND WIRE DRIVE  
MOTOR  
When the control board receives an activation  
command from the trigger circuit the control  
board activates the gas solenoid, output  
contactor, and the wire drive motor. The control  
board monitors the motor’s tach feedback  
signals and compares these to the wire speed  
control setting. The proper armature voltage is  
then applied to the wire drive motor. The drive  
motor speed is thus controlled which in turn  
regulates the electrode wire feed speed through  
the gun.  
Two thermostats are included in the trigger  
circuitry. If either of these thermostats would  
“open”, the trigger circuit would be interrupted  
and the machine’s output would be disabled.  
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.  
POWER MIG 200  
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E-5  
E-5  
THEORY OF OPERATION  
PROTECTIVE DEVICES AND CIRCUITS  
THERMAL AND OVERLOAD PROTECTION  
WIREFEED OVERLOAD PROTECTION  
The POWER MIG 200 has solid state overload  
protection of the wire drive motor. If the motor  
becomes overloaded, the protection circuitry turns off  
the wire feed speed and gas solenoid. Check for  
proper size tip liner, drive rolls, and any obstructions  
or bends in the gun cable. Check for any other  
factors that would impede the wire feeding. To  
resume welding, simply pull the trigger. There is no  
circuit breaker to reset, as the protection is done with  
reliable solid state electronics.  
The POWER MIG 200 has two built-in protective  
thermostats that respond to excessive temperatures.  
One is located on the main transformer. The other  
thermostat is located on the output rectifier heat sink  
assembly. They open the wire feed and welder  
output circuits if the machine exceeds the maximum  
safe operating temperature. This can be caused by  
a frequent overload or high ambient temperature.  
The thermostats are self-resetting once the machine  
cools sufficiently. If the thermostat shutdown is caused  
by excessive output or duty cycle and the fan is  
operating normally, the power switch may be left on  
and the reset should occur within a 15 minute period.  
If the fan is not turning or the air intake louver are  
obstructed, then the input power must be removed  
and the fan problem or air obstruction must be  
corrected.  
POWER MIG 200  
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E-6  
E-6  
NOTES  
POWER MIG 200  
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Section F  
Section F  
TABLE OF CONTENTS  
- TROUBLESHOOTING AND REPAIR SECTION -  
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F  
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . .  
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . .  
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Main Transformer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Drive Motor and Tachometer Feedback Test . . . . . . . . . . . . . .  
Output Bridge Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Voltage Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . .  
Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wire Drive Motor Assembly Replacement . . . . . . . . . . . . . . . . . . . .  
Output Diode Bridge Rectifier Replacement . . . . . . . . . . . . . . . . . .  
Output Capacitors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Main Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Fan Blade/Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Output Contactor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
F-2  
F-3  
F-4  
F-11  
F-11  
F-15  
F-19  
F-21  
F-23  
F-27  
F-27  
F-29  
F-33  
F-37  
F-41  
F-47  
F-49  
F-52  
WARNING  
ELECTRIC SHOCK can kill.  
• Never work on the inside of the machine without removing the  
input power. You can receive a life threatening electrical shock if  
you fail to do this. Only qualified technicians should perform  
installation, maintenance, and troubleshooting work on the  
machine.  
POWER MIG 200  
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F-2  
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.  
This Troubleshooting Guide is provided to  
help you locate and repair possible machine  
malfunctions. Simply follow the three step  
procedure below.  
Step 3. PERFORM COMPONENT TESTS.  
The last column labeled “RECOMMENDED  
COURSE OF ACTION” lists the most likely  
components that may have failed in your  
machine. It also specifies the appropriate  
test procedure to verify that the subject  
component is either bad or good. If there  
are a number of possible components,  
check the components in the order listed to  
eliminate one possibility at a time until you  
locate the cause of your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM  
(SYMPTOMS)”. This column describes  
possible symptoms that the machinery may  
exhibit. Find the listing that best describes  
the symptom that the machine is exhibiting.  
Symptoms are grouped according to:  
feeding problems and function problems.  
All the necessary test specifications and  
repair procedures are described in detail  
following the troubleshooting guide. All  
electrical test points, terminal strips,  
junctions, etc., can be found on the  
electrical wiring diagrams and schematics  
in the Electrical Diagram Section.  
Step 2. PERFORM EXTERNAL TESTS.  
The second column labeled “POSSIBLE  
AREAS OF MISADJUSTMENT(S)” lists the  
obvious external possibilities that may  
contribute to the machine symptom.  
Perform these tests/checks in the order  
listed. In general, these tests can be  
conducted without removing the case wrap-  
around cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the  
tests/repairs safely, contact the Lincoln Electric Service Department for technical  
troubleshooting assistance before you proceed. Call 1-800-833-9353.  
POWER MIG 200  
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F-3  
F-3  
TROUBLESHOOTING AND REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
- Tools which come in contact with the PC  
board must be either conductive, anti-static or  
static-dissipative.  
WARNING  
ELECTRIC SHOCK  
can kill.  
- Remove the PC board from the static-shield-  
ing bag and place it directly into the equip-  
ment. Don’t set the PC board on or near paper,  
plastic or cloth which could have a static  
charge. If the PC board can’t be installed  
immediately, put it back in the static-shielding  
bag.  
•
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.  
- If the PC board uses protective shorting  
jumpers, don’t remove them until installation is  
complete.  
CAUTION  
Sometimes machine failures appear to be due  
to PC board failures. These problems can  
sometimes be traced to poor electrical con-  
nections. To avoid problems when trou-  
bleshooting and replacing PC boards, please  
use the following procedure:  
- If you return a PC board to The Lincoln  
Electric Company for credit, it must be in the  
static-shielding bag. This will prevent further  
damage and allow proper failure analysis.  
4. Test the machine to determine if the  
failure symptom has been corrected by  
the replacement PC board.  
1. Determine to the best of your technical  
ability that the PC board is the most  
likely component causing the failure  
symptom.  
NOTE: It is desirable to have a spare  
(known good) PC board available for PC  
board troubleshooting.  
2. Check for loose connections at the PC  
board to assure that the PC board is  
properly connected.  
NOTE: Allow the machine to heat up so that  
all electrical components can reach their  
operating temperature.  
3. If the problem persists, replace the  
suspect PC board using standard  
practices to avoid static electrical  
damage and electrical shock. Read the  
warning inside the static resistant bag  
and perform the following procedures:  
5. Remove the replacement PC board and  
substitute it with the original PC board  
to recreate the original problem.  
a. If the original problem does not  
reappear by substituting the original  
board, then the PC board was not  
the problem. Continue to look for  
bad connections in the control wiring  
harness, junction blocks, and  
terminal strips.  
PC board can be  
damaged by static  
electricity.  
- Remove your body’s  
static charge before  
b. If the original problem is recreated by  
the substitution of the original board,  
then the PC board was the problem.  
Reinstall the replacement PC board  
and test the machine.  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
opening  
the  
static-  
shielding bag. Wear an  
anti-static wrist strap. For  
safety, use a 1 Meg ohm  
resistive cord connected  
to a grounded part of the  
equipment frame.  
Workstations  
6. Always indicate that this procedure was  
followed when warranty reports are to  
be submitted.  
- If you don’t have a wrist  
strap, touch an un-  
painted, grounded, part of the equipment  
frame. Keep touching the frame to prevent  
static build-up. Be sure not to touch any  
electrically live parts at the same time.  
NOTE: Following this procedure and writing  
on the warranty report, “INSTALLED AND  
SWITCHED PC BOARDS TO VERIFY PROB-  
LEM,” will help avoid denial of legitimate PC  
board warranty claims.  
POWER MIG 200  
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F-4  
F-4  
TROUBLESHOOTING AND REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide – See Wiring Diagrams for location of specified  
components and for troubleshooting of specific circuits.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical  
damage is evident.  
1. Contact Lincoln Electric  
Service Department 1-800-  
833-9353 (WELD).  
1. Contact your local Lincoln  
Electric authorized field service  
facility.  
1. Check the input power switch  
(S1). It may be faulty.  
1. Make certain the input power  
switch (S1) is in the “ON”  
position.  
The machine is dead--no open  
circuit voltage and no wire feed  
when the gun trigger is activated.  
The cooling fan is not running.  
2. Check for broken or missing  
wires at the reconnect panel.  
2. Check the input voltage at the  
machine. The input voltage  
must match the rating plate and  
the reconnect panel.  
3. Perform the Main Transformer  
Test.  
3. Check for blown or missing  
fuses in the input lines.  
There is no open circuit voltage  
or wire feed when the gun trigger  
is activated. The cooling fan is  
running.  
1. Make sure the input voltage is 1. The baffle mounted rectifier  
correct and matches the  
nameplate rating and reconnect  
panel configuration.  
bridge may be faulty. Check  
and replace if necessary.  
2. Perform the Main Transformer  
2. One of the two thermostats may  
be open due to machine  
overheating. If the machine  
Test.  
3. Check the thermostats and  
associated leads for loose or  
faulty connections. See the  
wiring diagram.  
operates normally after  
a
cooling off period then check for  
proper fan operation and  
ventilation. Make certain the  
machine’s duty cycle is not  
being exceeded.  
4. The  
internal  
triggering  
circuit/plugs may be faulty. See  
the wiring diagram.  
5. The control board may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-800-833-9353.  
POWER MIG 200  
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F-5  
F-5  
TROUBLESHOOTING AND REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide – See Wiring Diagrams for location of specified  
components and for troubleshooting of specific circuits.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS (Continued)  
(continued from previous page)  
3. Check the gun trigger leads.  
Leads #324 to #325 should  
have continuity (zero ohms)  
when the gun trigger is activat-  
ed. If not, the gun trigger or  
cable may be faulty. Check or  
replace.  
4. If a spool gum option kit is  
installed, check to make sure it  
is set to the “normal” position if  
using the POWER MIG 200 built  
in wire feeder.  
When the gun trigger is activated 1. Make sure the gun cable and 1. Check the output selector  
and the wire feeds normally, but  
there is no open circuit voltage.  
work cables are connected  
properly and in good condition.  
switch for proper operation and  
good connections.  
2. Make sure the output selector 2. Perform the Output Contactor  
switch is in a good condition  
position and not between posi-  
tions.  
Test.  
3. Perform the Output Bridge  
Rectifier Test.  
4. Perform the Main Transformer  
Test.  
5. Check the heavy current carry-  
ing leads between the output  
selector switch, output contac-  
tor, output bridge rectifier, and  
the output terminals for loose or  
faulty connections. See Wiring  
Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-800-833-9353.  
POWER MIG 200  
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F-6  
F-6  
TROUBLESHOOTING AND REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide – See Wiring Diagrams for location of specified  
components and for troubleshooting of specific circuits.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS (Continued)  
Output voltage and wire feed speed 1. Remove the gun assembly. If 1. Check for “shorts” in the trigger  
is present when the gun trigger is  
NOT activated.  
the problem is resolved, the gun  
assembly is faulty. Repair or  
replace. If the problem is NOT  
resolved, the fault is within the  
POWER MIG 200 machine.  
circuitry within the POWER MIG  
200 machine. See the wiring  
diagram.  
2. The control board may be faulty.  
The machines output is low. Welds 1. Check the input voltage. Make  
1. Check for loose or faulty con-  
nections on the heavy current  
carrying leads inside the  
POWER MIG 200. See the  
Wiring Diagram.  
are “cold”. The weld beads are  
rounded or “humped” demonstrat-  
ing poor wetting into the plate. The  
machine cannot obtain full rated  
output of 200 amps at 22VDC.  
sure the machine is configured  
properly for the input voltage  
being applied.  
2. Make sure the settings for wire  
feed speed and voltage are cor-  
rect for the process being used.  
2. The output capacitors may be  
faulty. Check for loose connec-  
tions at the capacitors. Also  
check for leaky capacitors.  
Replace if necessary.  
3. Make sure the electrode polarity  
is correct for the process being  
used.  
WARNING: The liquid electrolyte  
in these capacitors is toxic.  
Avoid contact with any portion of  
your body.  
4. Check the welding cables and  
gun for loose or faulty connec-  
tions.  
3. The output selector switch may  
be faulty. Check for good con-  
tact and continuity (zero ohms)  
through the switch. See the  
Wiring Diagram.  
4. Perform the Output Contactor  
Test.  
5. Perform the Output Bridge  
Rectifier Test.  
6. Perform the Main Transformer  
Test.  
1. Perform the Output Contactor  
The output voltage is continuous 1. The output contactor may be  
Test.  
when the gun trigger is NOT activat-  
ed. The wire feed functions normal-  
ly.  
stuck closed.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-800-833-9353.  
POWER MIG 200  
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F-7  
F-7  
TROUBLESHOOTING AND REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide – See Wiring Diagrams for location of specified  
components and for troubleshooting of specific circuits.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
FUNCTION PROBLEMS  
1. If a spool gun adapter is installed,  
make certain the toggle switch in  
the spool gun kit in the correct  
position.  
There is no gas flow when the gun  
trigger is activated . The wire feeds  
and the arc voltage is present.  
1. Check plug J1 on the control board  
for loose or faulty connections. See  
wiring diagram.  
2. Check the gas solenoid by discon-  
necting it from leads #108A and  
#116A&B. Apply a 12VDC external  
supply to the solenoid. If the sole-  
noid does NOT activate then it may  
be faulty. Replace.  
2. If a spool gun adapter is NOT  
installed, make certain the jumper  
plug is installed in J5. See the  
wiring diagram.  
3. Check the gas source and hoses  
for kinks or leaks.  
1. Check for a mechanical restric-  
tion in the wire feed path. The  
gun may be clogged.  
The machine stops feeding wire  
while welding. When the gun trig-  
ger is released and pulled again,  
the wire feed starts.  
1. Check the motor armature current.  
Normal armature current is 2.0 to 2.7  
amps maximum. If the motor arma-  
ture current is normal, and the motor  
continues to shut-off, the control  
board may be faulty. Replace.  
2. Make sure the drive rolls and  
guide plates are clean and are  
the correct size.  
2. If the motor armature current is high  
(over 2.7 amps) and there are NO  
restrictions in the wire feeding path  
then the motor or gearbox may be  
defective. Replace.  
3. Check the spindle for ease of  
rotation.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the  
Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353  
POWER MIG 200  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-8  
F-8  
TROUBLESHOOTING AND REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide – See Wiring Diagrams for location of specified  
components and for troubleshooting of specific circuits.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
WIRE FEEDING PROBLEMS  
1. The gun cable may be kinked or  
twisted.  
Rough wire feeding or the wire will  
not feed but the drive rolls are turn-  
ing.  
2. Check the drive roll tension and  
the position of the grooves.  
3. Electrode may be rusted or dirty.  
4. The contact tip may be damaged  
or not the correct size.  
5. Check the wire spindle for ease of  
rotation.  
6. Make certain the gun is pushed all  
the way into the gun mount and  
properly seated.  
No control of wire feed speed.  
Other machine functions are nor-  
mal.  
1. The wire speed control potentiometer  
may be faulty. Check or replace.  
Normal potentiometer resistance is  
10K ohms.  
1. The wire feed speed control may  
be dirty. Rotate several times and  
check if the problem is resolved.  
2. Perform the Wire Drive Motor and  
Tachometer Feedback Test.  
3. The control board may be faulty.  
There is no wire feed when the gun  
trigger is activated. Normal open  
circuit weld voltage is present and  
the gas solenoid functions normally.  
1. Perform the Wire Drive Motor and  
1. Check for adequate wire supply.  
Tachometer Feedback Test.  
2. If the drive rolls are turning, check  
for a mechanical restriction in the  
wire feed path.  
2. The wire speed control potentiometer  
may be faulty. Check or replace.  
Normal potentiometer resistance is  
10K ohms.  
3. The gun liner may be clogged.  
Check or replace.  
3. The control board may be faulty.  
4. If the drive rolls are not turning  
when the gun trigger is activated,  
contact your local Lincoln Electric  
Authorized Field Service Facility.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the  
Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353  
POWER MIG 200  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-9  
F-9  
TROUBLESHOOTING AND REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide – See Wiring Diagrams for location of specified  
components and for troubleshooting of specific circuits.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
WELDING PROBLEMS  
Poor arc striking with electrode  
sticking or blasting off.  
1. Make sure the settings for wire 1. The output capacitors may be faulty.  
feed speed and voltage are cor-  
rect for the process being used.  
Check for loose connections at the  
capacitors. Also check for leaky  
capacitors. Replace if necessary.  
2. Make certain the gas shielding is  
correct for the process being WARNING: The liquid electrolyte in  
used.  
these capacitors is toxic. Avoid con-  
tact with any portion of your body.  
3. Make sure the machine’s recon-  
nect panel is configured properly 2. Perform the Output Diode Rectifier  
for the input voltage being  
applied.  
Test.  
The arc is unstable and or “hunting”  
1. Check for a worn or melted con- 1. Check for loose or faulty connections  
tact tip.  
at the output terminals, choke, output  
capacitors, output selector switch,  
output contactor, and all heavy cur-  
rent carrying leads. See the wiring  
diagram.  
2. Check for loose or faulty connec-  
tions on the work and gun cables.  
3. Make sure the electrode polarity  
is correct for the welding process 2. Check the output selector switch for  
being used.  
proper operation and good connec-  
tions.  
4. Check for rusted or dirty electrode  
wire.  
3. The output capacitors may be faulty.  
Check for loose connections at the  
capacitors. Also check for leaky  
capacitors. Replace if necessary.  
5. Make sure the machine’s settings  
and shielding gas are correct for  
the process being used .  
WARNING: The liquid electrolyte in  
these capacitors is toxic. Avoid con-  
tact with any portion of your body.  
4. Perform the Output Bridge Rectifier  
Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the  
Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353  
POWER MIG 200  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-10  
F-10  
TROUBLESHOOTING AND REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
Troubleshooting Guide – See Wiring Diagrams for location of specified  
components and for troubleshooting of specific circuits.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
WELDING PROBLEMS  
The weld bead is narrow or ropy. 1. Make sure the welding proce- 1. Perform the Output Bridge Rectifier  
May have porosity with the elec-  
trode stubbing into the plate.  
dures and electrode polarity are  
correct for the process being  
used.  
Test.  
2. The output capacitors may be faulty.  
Check for loose connections at the  
capacitors. Also check for leaky  
capacitors. Replace if necessary.  
2. Make certain the shielding gas is  
correct and the flow is proper.  
3. Make sure the weld joint is not WARNING: The liquid electrolyte in  
“contaminated”.  
these capacitors is toxic. Avoid con-  
tact with any portion of your body.  
The contact tip seizes in the gas dif- 1. The tip is being over heated due  
fuser.  
to excessive current and/or high  
duty cycle.  
2. A light application of high temper-  
ature anti-seize lubricant may be  
applied to the contact tip threads.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the  
Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353  
POWER MIG 200  
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F-11  
F-11  
TROUBLESHOOTING AND REPAIR  
MAIN TRANSFORMER TEST  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in  
danger to the technician or machine operator and will invalidate your factory  
warranty. For your safety and to avoid electrical shock please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
TEST DESCRIPTION  
This test will determine if the correct voltages are being applied.  
a. Applied to the primary windings of the main transformers.  
b. Induced on the secondary and auxiliary windings of the main transformer.  
MATERIALS NEEDED  
3/8” Nutdriver  
5/16” Nutdriver  
Volt-ohmmeter  
This procedure takes approximately 40 minutes to perform.  
POWER MIG 200  
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F-12  
F-12  
TROUBLESHOOTING AND REPAIR  
MAIN TRANSFORMER TEST (continued)  
FIGURE F.1. – OUTPUT SELECTOR SWITCH TERMINALS  
X4 X5  
X3  
X6  
X2  
X7  
X8  
6. Locate leads X9 and X10. See Figure  
TEST PROCEDURE  
F.3.  
WARNING  
7. Connect main input power to the  
machine.  
THE ON/OFF POWER SWITCH will be  
“hot” during these tests.  
8. Turn the POWER MIG 200 ON/OFF  
Power Switch to the ON position.  
NOTE: Secondary voltages will vary  
proportionately with the primary input  
voltage.  
WARNING  
ELECTRIC SHOCK can kill.  
1. Disconnect the main input power  
supply to the machine.  
• Do not touch electrically live  
parts such as output terminals  
or internal wiring.  
2. Remove the case top and side panels  
with a 3/8” nutdriver.  
• All input power must be electri-  
cally disconnected before pro-  
ceeding.  
3. Remove the tool tray with a 5/16” nut  
driver.  
9. Carefully make the following voltage  
tests. See Table F.1.  
4. Locate leads X2 thru X8 located on  
the output selector switch. See Figure  
F.1.  
10. Turn Off the machine.  
11. If any of the voltages are incorrect  
or missing, check for loose or broken  
connections between the main  
transformer and the test points.  
5. Locate lead X1 located on the output  
rectifier assembly. See Figure F.2.  
POWER MIG 200  
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F-13  
F-13  
TROUBLESHOOTING AND REPAIR  
MAIN TRANSFORMER TEST (continued)  
FIGURE F.2. – LEAD X1  
X1  
X9  
X10  
FIGURE F.3. – LEAD X9 & X10  
POWER MIG 200  
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F-14  
F-14  
TROUBLESHOOTING AND REPAIR  
TABLE F.1. Test Points  
INPUT VOLTAGE  
230 VAC  
TEST POINTS  
X1-X2  
EXPECTED VOLTAGE READING  
11.9-13.0 VAC  
230 VAC  
X1-X3  
14.1-15.2 VAC  
16.2-17.5 VAC  
18.4-19.7 VAC  
20.5-22.0 VAC  
22.7-24.2 VAC  
24.8-26.5 VAC  
26.9-28.8 VAC  
X1-X4  
230 VAC  
230 VAC  
230 VAC  
230 VAC  
230 VAC  
230 VAC  
X1-X5  
X1-X6  
X1-X7  
X1-X8  
X9-X10  
12. If ALL the voltages tested are incorrect  
or missing, test for correct nameplate  
input voltage between the H1 lead at the  
ON/OFF POWER SWITCH to H2 or H3  
at the reconnect panel. Voltage tested  
will vary depending on input voltage con-  
nection. See wiring diagram for test  
point locations.  
13. If the correct nameplate voltage is being  
applied to the main transformer and one  
or more of the secondary voltages are  
missing or are incorrect, the main trans-  
former may be faulty. Replace.  
14. When test is complete, replace tool tray,  
case sides and top.  
A. If the input voltage test is incorrect,  
check for loose or broken leads between  
the reconnect panel and the ON/OFF  
POWER SWITCH.  
B. Test the ON/OFF POWER SWITCH for  
proper operation.  
POWER MIG 200  
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F-15  
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.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
TEST DESCRIPTION  
This test will determine if the wire drive motor and voltage feedback circuit are functioning  
properly.  
MATERIALS NEEDED  
5/16” Nutdriver  
Volt-Ohmmeter  
This procedure takes approximately 30 minutes to perform.  
POWER MIG 200  
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F-16  
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  
TEST PROCEDURE  
2. Open the side panels and remove the  
NOTE: POLARITY MUST BE OBSERVED  
tool tray using a 5/16” nutdriver.  
FOR THESE TESTS.  
3. Locate plug J4 on the wiring harness.  
See Wiring Diagram.  
Test for correct wire drive motor armature  
voltage.  
4. Locate the black and white armature  
leads on plug J4. See Figure F.4.  
1. Disconnect main input power to the  
machine.  
POWER MIG 200  
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F-17  
F-17  
TROUBLESHOOTING AND REPAIR  
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST  
(continued)  
5. Make the following voltage tests:  
2. Locate plug J4.  
WARNING  
3. Locate the tach leads on plug J4. See  
ELECTRIC SHOCK can kill.  
Figure F.5.  
• Do not touch electrically live  
parts such as output terminals  
4. Connect the main input power to the  
or internal wiring.  
machine.  
• All input power must be electri-  
cally disconnected before pro-  
ceeding.  
5. Make the following voltage tests:  
a. Turn the machine OFF between each  
WARNING  
test.  
ELECTRIC SHOCK can kill.  
b. Carefully insert the meter probes into  
the lead side of plug J4. See Figure  
F.4.  
• Do not touch electrically live  
parts such as output terminals  
or internal wiring.  
• All input power must be electri-  
cally disconnected before pro-  
ceeding.  
c. Turn the machine ON and pull the gun  
trigger to conduct the voltage test.  
a. Turn the machine OFF between each test.  
FROM LEAD  
FROM LEAD  
FROM LEAD  
Black  
Armature  
Lead  
White  
Armature  
Lead  
2-29 VDC  
(varies depend-  
ing on wire feed  
speed)  
b. Carefully insert the meter probes into the  
lead side of plug J4.  
FROM LEAD  
FROM LEAD  
FROM LEAD  
6. If the voltage to the wire drive motor arma-  
ture is zero, check the wires between plug  
J4 and the wire drive motor. Also check  
the electrical connector J5 for proper con-  
nections and jumper plug. See the Wiring  
Diagram.  
Black (-)  
Red (+)  
5-6 VDC  
6. If the 5-6 VDC is present, check the leads  
to the tachometer circuit.  
7. If all wires and connectors are good and  
the voltage to the drive motor armature is 7. If the leads are okay and 5-6 VDC is pre-  
zero, the control PC board may be faulty.  
Replace the control PC board.  
sent, the correct voltage is being received  
from the control PC board. Continue with  
the supply voltage to tachometer test.  
8. If the motor is running at high speed and  
the armature voltage is high and uncon- 8. If the 5-6 VDC is not present and the leads  
trollable, Proceed with the tachometer test.  
are okay, the control PC board may be  
faulty, replace the control PC board. Also  
check plug J5 and the jumper plug. See  
Wiring Diagram.  
TEST FOR SUPPLY VOLTAGE TO  
TACHOMETER  
1. Disconnect the main AC input power to the  
machine.  
POWER MIG 200  
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F-18  
F-18  
TROUBLESHOOTING AND REPAIR  
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST  
(continued)  
c. Turn the machine ON and pull the  
TEST FOR FEEDBACK VOLTAGE  
TO CONTROL BOARD  
gun trigger to conduct the voltage  
test.  
1. Disconnect the main AC input power to  
EXPECTED  
VOLTAGE  
TO LEAD  
FROM LEAD  
the machine.  
2. Locate plug J4 and the tach leads.  
See Figure F.5.  
3.0 TO 4.0  
VDC  
BLUE (+)  
Black (-)  
3. Connect main input power to the  
machine.  
5. If the 3.0 to 4.0 VDC is present, the  
tachometer circuit is sending the correct  
feedback signal to the control PC board.  
Check the leads and plug J5. See the  
Wiring Diagram.  
4. Make the following voltage tests:  
WARNING  
ELECTRIC SHOCK can kill.  
6. If the 3.0 to 4.0 VDC is NOT present  
or NOT correct, the control PC board  
is not receiving the proper feedback  
voltage from the tachometer circuit.  
• Do not touch electrically live  
parts such as output terminals  
or internal wiring.  
• All input power must be electri-  
cally disconnected before pro-  
ceeding.  
7. If the leads are okay, the tachometer  
circuit may be faulty, replace the  
tachometer circuit.  
a. Turn the machine OFF between  
each test.  
8. Replace the tool tray.  
b. Carefully insert the meter probes  
into the lead side of plug J4. See  
Figure F5.  
FIGURE F.5. – PLUG J4  
Black  
Tach  
Black  
Arm  
White  
Arm  
J11  
Blue  
Tach  
Red  
Tach  
POWER MIG 200  
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F-19  
F-19  
TROUBLESHOOTING AND REPAIR  
OUTPUT BRIDGE RECTIFIER TEST  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in  
danger to the technician or machine operator and will invalidate your factory  
warranty. For your safety and to avoid electrical shock please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
TEST DESCRIPTION  
This test will determine if a diode is “shorted” or “leaky”. See the machine waveform  
section in this manual for normal and abnormal output wave forms.  
MATERIALS NEEDED  
Analog Volt-ohmmeter or Diode Tester  
3/8” Nutdriver  
1/2” Nutdriver  
This procedure takes approximately 20 minutes to perform.  
POWER MIG 200  
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F-20  
F-20  
TROUBLESHOOTING AND REPAIR  
OUTPUT BRIDGE RECTIFIER TEST (continued)  
4. Test for “shorted” or “leaky” diodes by  
TEST PROCEDURE  
checking from the anodes to the cathodes  
of the diode heatsink plates. The  
readings should be high resistance in  
one polarity and low resistance in the  
opposite polarity.  
1. Remove input power to the POWER  
MIG 200 machine.  
2. Using the 3/8” nutdriver, remove the left  
case side.  
5. If any of the diodes are “leaky” or  
“shorted” the output rectifier assembly  
should be replaced.  
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.  
6. When the test is complete, replace the  
negative output lead previously removed.  
7. Replace the left case side.  
NOTE: Do not disassemble the rectifier  
assembly.  
Figure F.6. Rectifier Test Points  
+
-
Negative Lead  
POWER MIG 200  
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F-21  
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.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
TEST DESCRIPTION  
This test will determine if the contactor is functional.  
MATERIALS NEEDED  
12 VDC Supply  
Volt/Ohmmeter  
7/16” Wrench  
This procedure takes approximately 30 minutes to perform.  
POWER MIG 200  
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F-22  
F-22  
TROUBLESHOOTING AND REPAIR  
CONTACTOR TEST (Continued)  
7. If the contactor activates when the  
TEST PROCEDURE  
12VDC is applied, check the resistance  
between the two large terminals with  
the contactor activated. The resistance  
should be very low (0 to 1 ohm).  
1. Remove the input power to the POWER  
MIG 200 machine.  
2. Using the 5/16” Nutdriver, remove the  
8. If the resistance is “high” or “open”  
between the two large terminals when  
the contactor is activated, the contactor  
is faulty. Replace.  
tool tray.  
3. Locate and remove leads 106B, 106C  
and 107A from the contactor coil  
terminals. See Figure F.7. See the  
Wiring Diagram.  
9. If the contactor activates and the  
resistance between the terminals is low  
when the 12 VDC is applied, the  
contactor is good  
4. Using the 7/16” wrench, remove one  
lead from the contactors large terminals.  
See Figure F.7. See the Wiring Diagram.  
NOTE: When the contactor is not activated,  
the  
resistance  
between  
the  
5. Carefully apply 12 VDC to the contactor  
coil leads. (small terminals)  
terminals should be very high  
(infinite). If the resistance is always  
low, the contacts are “stuck” and  
the contactor is faulty. Replace.  
CAUTION  
Do not leave the 12 VDC applied to the  
contactor coil for a prolonged period of  
time (15 seconds maximum). Damage  
to contactor may result.  
10. When the test is complete, replace  
leads 106B, 106C and 107A.  
11. Replace the lead previously removed  
from one of the contactor large  
terminals.  
6. If the contactor does not activate when  
the 12VDC is applied, the contactor is  
faulty. Replace.  
12. Replace the tool tray.  
Figure F.7. Contactor Terminals and Leads  
106B  
106C  
107A  
Output  
Contactor  
POWER MIG 200  
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F-23  
F-23  
TROUBLESHOOTING AND REPAIR  
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED  
(MAX TAP “G”)  
0 Volts  
10.0 V  
5 ms  
MACHINE LOADED TO 200 AMPS AT 22 VDC  
SCOPE SETTINGS  
This is a typical DC output voltage wave-  
form generated from a properly operat- Volts/Div.................................10V/Div  
ing machine. Note that each vertical  
division represents 10 volts and that Horizontal Sweep.................5 ms/Div  
each horizontal division represents 5  
milliseconds in time. The machine was Coupling........................................DC  
loaded with a resistance grid bank.  
Trigger....................................Internal  
NOTE: Scope probes connected at  
machine output terminals: (+)  
probe to electrode, (-) probe to  
work.  
POWER MIG 200  
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F-24  
F-24  
TROUBLESHOOTING AND REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”)  
0 Volts  
20.0 V  
1.0 ms  
SCOPE SETTINGS  
This is a typical DC output voltage wave-  
form generated from a properly operat- Volts/Div.................................20V/Div  
ing machine. Note that each vertical  
division represents 20 volts and that Horizontal Sweep..............1.0 ms/Div  
each horizontal division represents 1.0  
milliseconds in time.  
Coupling........................................DC  
NOTE: Scope probes connected at Trigger....................................Internal  
machine output terminals: (+)  
probe to electrode, (-) probe to  
work.  
POWER MIG 200  
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F-25  
F-25  
TROUBLESHOOTING AND REPAIR  
ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE  
LOADED (MAX TAP “G”)  
ONE OUTPUT DIODE NOT FUNCTIONING  
0 Volts  
20.0 V  
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 func- Volts/Div.................................20V/Div  
tioning. Note the increased ripple con-  
tent. One diode was disconnected to Horizontal Sweep.................5 ms/Div  
simulate an open or non-functioning out-  
put diode. Each vertical division repre- Coupling........................................DC  
sents 20 volts and each horizontal divi-  
sion represents 5 milliseconds in time. Trigger....................................Internal  
The machine was loaded with a resis-  
tance grid bank.  
NOTE: Scope probes connected at  
machine output terminals: (+)  
probe to electrode, (-) probe to  
work.  
POWER MIG 200  
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F-26  
F-26  
TROUBLESHOOTING AND REPAIR  
ABNORMAL OPEN CIRCUIT VOLTAGE  
OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”)  
0 Volts  
20.0 V  
5 ms  
SCOPE SETTINGS  
This is NOT a typical DC output voltage  
waveform. The output capacitors are Volts/Div.................................20V/Div  
not functioning. Note the lack of “filter-  
ing” in the output waveform. The output Horizontal Sweep.................5 ms/Div  
capacitor bank was disconnected. Each  
vertical division represents 20 volts and Coupling........................................DC  
each horizontal division represents 5  
milliseconds in time.  
Trigger....................................Internal  
NOTE: Scope probes connected at  
machine output terminals: (+)  
probe to electrode, (-) probe to  
work.  
POWER MIG 200  
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F-27  
F-27  
TROUBLESHOOTING AND REPAIR  
CONTROL BOARD REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in  
danger to the technician or machine operator and will invalidate your factory  
warranty. For your safety and to avoid electrical shock please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the control board for  
replacement.  
MATERIALS NEEDED  
5/16” Nutdriver  
This procedure takes approximately 20 minutes to perform.  
POWER MIG 200  
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F-28  
F-28  
TROUBLESHOOTING AND REPAIR  
CONTROL BOARD REPLACEMENT (continued)  
PROCEDURE  
6. Carefully remove the control board.  
1. Remove power to the machine.  
7. Mount the new board to the nylon mounting  
pins.  
2. Using a 5/16” nutdriver, remove the three  
screws securing the tool tray.  
8. Reconnect any plugs or leads previously  
removed.  
3. Locate the control board.  
4. Disconnect all associated plugs and leads  
connected to the control board.  
9. Replace the tool tray previously removed.  
5. Depress the retaining pins on the sides of the  
four nylon mounts to release the control  
board. See Figure F.8.  
FIGURE F.8. - CONTROL BOARD MOUNTING PINS  
DEPRESS  
LOCKING TAB ON  
MOUNTING PIN  
POWER MIG 200  
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F-29  
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.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the wire drive and tachometer  
for repair or replacement.  
MATERIALS NEEDED  
5/16” Nutdriver  
9/16” Nutdriver  
Pliers  
Small Flathead Screwdriver  
This procedure takes approximately 50 minutes to perform.  
POWER MIG 200  
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F-30  
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.  
1. Remove power to the machine.  
2. Lift cover to gain access to the wire drive.  
6. Using a 5/16” nutdriver, remove the two  
See Figure F.9.  
screws on the case front assembly. See  
Figure F.11.  
3. Using a pair of pliers, disconnect the gas  
hose from the bottom of the wire drive.  
See Figure F.10.  
7. Carefully maneuver the wire drive assem-  
bly out the side of the machine to gain  
access to plug J4. See Wiring Diagram.  
4. Using a 9/16” nut driver, remove the thick  
black positive lead located just above the  
gas hose. See Figure F.10.  
8. Disconnect plug J4.  
NOTE: Disconnect lead from the wire drive  
motor assembly, not the machine.  
POWER MIG 200  
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F-31  
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. - MOUNTING SCREW LOCATIONS  
POWER MIG 200  
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F-32  
F-32  
TROUBLESHOOTING AND REPAIR  
WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued)  
1. Place the new wire drive assembly into its 5. Using a 3/4” nut driver, replace the thick  
proper position.  
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.  
4. Replace all mounting screws previously  
removed.  
POWER MIG 200  
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F-33  
F-33  
TROUBLESHOOTING AND REPAIR  
OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in  
danger to the technician or machine operator and will invalidate your factory  
warranty. For your safety and to avoid electrical shock please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output diode bridge  
rectifier for repair or replacement.  
MATERIALS NEEDED  
3/8” Nutdriver  
1/2” Nutdriver  
5/16” Nutdriver  
This procedure takes approximately 50 minutes to perform.  
POWER MIG 200  
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F-34  
F-34  
TROUBLESHOOTING AND REPAIR  
OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)  
PROCEDURE  
7. Using a 1/2” nutdriver remove the three bolts  
mounting the bracket to the rectifier. The rectifi-  
er is now ready for repair or replacement. See  
Figure F.13.  
1. Using a 3/8” nutdriver, remove the left side of the  
case wraparound cover.  
2. Locate the output diode bridge rectifier. See  
8. Mount the new rectifier to the mounting bracket  
Figure F.12.  
using the three 1/2” bolts.  
3. Using a 1/2” nutdriver label and remove the four  
9. Carefully manipulate the rectifier and mounting  
thick black leads connected to the rectifier.  
bracket as a one back into the machine to its  
NOTE: Be sure to label lead terminals also.  
proper location.  
Take note of washer placement upon removal.  
10. Mount the unit to the bottom of the machine  
4. Label and remove leads 104A and 104B. See  
using the four 5/16” mounting bolts previously  
removed.  
Wiring Diagram.  
5. Using a 5/16” nutdriver locate and remove the  
11. Reconnect leads 104A and 104B previously  
four bolts mounting the rectifier bracket to the  
removed.  
bottom of the machine. These bolts can be  
accessed easily from the bottom of the machine.  
See Figure F.13.  
12. Reconnect the four thick black leads previously  
labeled and removed using a 1/2” nutdriver.  
6. Carefully manipulate the output diode bridge  
13. Replace the left side of the case wraparound  
rectifier and the mounting bracket out of the left  
cover.  
side of the machine.  
FIGURE F.12. - OUTPUT DIODE BRIDGE RECTIFIER LOCATION  
OUTPUT DIODE  
BRIDGE  
RECTIFIER  
POWER MIG 200  
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F-35  
F-35  
TROUBLESHOOTING AND REPAIR  
OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)  
FIGURE F.13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET  
5/16" Mounting  
Bracket Mounting  
Bolts  
1/2" Rectifier  
Mounting  
Mounting Bolts  
Bracket  
POWER MIG 200  
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F-36  
F-36  
NOTES  
POWER MIG 200  
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F-37  
F-37  
TROUBLESHOOTING AND REPAIR  
OUTPUT CAPACITORS REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in  
danger to the technician or machine operator and will invalidate your factory  
warranty. For your safety and to avoid electrical shock please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output capacitors for  
repair or replacement.  
MATERIALS NEEDED  
3/8” Nutdriver  
1/2” Wrench  
This procedure takes approximately 30 minutes to perform.  
POWER MIG 200  
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F-38  
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  
6. Place the new capacitor bank into its proper  
location inside the machine.  
side case wraparound cover. See Figure F.14.  
2. Locate capacitor bank. See Figure F.14.  
7. Replace the three 3/8” nuts and lock washers  
previously removed.  
3. Label and remove the five leads connected to  
the capacitor bank using a 1/2” wrench. Note  
washer position upon removal. See Figure  
F.15.  
8. Using a 1/2” wrench, reconnect the five labeled  
leads and associated washers previously  
removed.  
4. Using a 3/8” nutdriver, remove the three capac-  
itor bank nuts and lock washers from the three  
mounting bolts. See Figure F.15.  
9. Replace the lower right side case wraparound  
cover previously removed.  
FIGURE F.14. - CAPACITOR BANK LOCATION  
LOWER RIGHT  
CASE WRAPAROUND  
COVER  
CAPACITOR BANK  
ASSEMBLY  
POWER MIG 200  
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F-39  
F-39  
TROUBLESHOOTING AND REPAIR  
OUTPUT CAPACITORS REPLACEMENT (Continued)  
FIGURE F.15. - MOUNTING SCREW/BOLT LOCATIONS  
Lead Mounting  
Bolts  
3/8" Nuts &  
Lock washers  
(3 places)  
POWER MIG 200  
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F-40  
F-40  
NOTES  
POWER MIG 200  
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F-41  
F-41  
TROUBLESHOOTING AND REPAIR  
MAIN TRANSFORMER REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in  
danger to the technician or machine operator and will invalidate your factory  
warranty. For your safety and to avoid electrical shock please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the main transformer for  
repair or replacement.  
MATERIALS NEEDED  
3/8” Nutdriver  
7/16” Nutdriver  
1/2” Nutdriver  
5/16” Nutdriver  
Flathead Screwdriver  
This procedure takes approximately 80 minutes to perform.  
POWER MIG 200  
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F-42  
F-42  
TROUBLESHOOTING AND REPAIR  
MAIN TRANSFORMER REPLACEMENT (Continued)  
7. Using a 1/2” nutdriver, label and remove  
PROCEDURE  
lead X1 from the output diode bridge rectifi-  
er.  
1. Using a 3/8” nutdriver, remove both sides of  
the case wraparound cover.  
8. Using a 5/16” Nutdriver, open the rear  
access panel. See Figure F.20.  
2. Using a 5/16” nutdriver, remove the tool tray.  
9. Disconnect lead 118 from the rear access  
3. Locate the main transformer. See Figure  
F.16.  
panel. See Figure F.21.  
10. Feed lead 118 toward the inside of the  
machine.  
4. Label and disconnect leads X9, X10, 104B,  
& 104C. See Figure F.17.  
11. Cut any necessary cable ties.  
5. Using a flathead screwdriver, Label and dis-  
connect lead H1B and other associated lead  
connected to the same terminal. These  
leads are connected to the ON/OFF switch.  
See Figure F.17.  
12. Remove any necessary wiring harnesses.  
13. Disconnect lead 121. See Figure F.19.  
14. Using a 1/2” nutdriver, remove the four main  
transformer mounting bolts and associated  
washers. See Figure F.16.  
6. Using a 7/16” nutdriver, Label and discon-  
nect leads X8, X7, X6, X5, X4, X3, & X2 from  
the switch assembly. Note washer position  
upon removal. See Figure F.18.  
FIGURE F.16. - MAIN TRANSFORMER LOCATION  
Main Transformer  
1/2" Mounting  
Bolts  
POWER MIG 200  
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F-43  
F-43  
TROUBLESHOOTING AND REPAIR  
MAIN TRANSFORMER REPLACEMENT (Continued)  
15. Carefully maneuver the main transformer 5. Reconnect lead X1 to the output diode  
out the left side of the machine.  
bridge rectifier.  
NOTE: Two people may be needed to maneu- 6. Reconnect leads X8, X7, X6, X5, X4, X3, &  
ver the main transformer out of the  
machine.  
X2 previously removed from the switch  
assembly.  
7. Reconnect lead H1B and the other associat-  
ed lead connected to the same terminal.  
These leads are connected to the ON/OFF  
switch.  
REPLACEMENT  
1. Carefully maneuver the new main trans-  
former back into the machine and onto its  
mounting studs.  
8. Replace any necessary cable ties and wiring  
harnesses.  
2. Using a 1/2” nutdriver, mount the main trans-  
former in its proper position.  
9. Reconnect leads X9, X10, 104B, & 104C.  
See Wiring Diagram.  
3. Reconnect leads 118 and 121 previously  
removed.  
10. Using a 5/16” nutdriver, replace the tool tray.  
4. Using a 5/16” nutdriver, close the rear  
11. Using a 3/8” nutdriver, replace both sides of  
access panel previously opened.  
the case wraparound cover.  
FIGURE F.17. - LEADS X9, X10, 104B,104C, & H1B  
104B  
104C  
X9  
X10  
H1B  
POWER MIG 200  
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F-44  
F-44  
TROUBLESHOOTING AND REPAIR  
MAIN TRANSFORMER REPLACEMENT (Continued)  
FIGURE F.18. - LEADS SWITCH LEADS  
X4 X5  
X3  
X6  
X2  
X7  
X8  
+
-
121  
118  
FIGURE F.19. - LEAD 121 & 118  
POWER MIG 200  
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F-45  
F-45  
TROUBLESHOOTING AND REPAIR  
MAIN TRANSFORMER REPLACEMENT (Continued)  
FIGURE F.20. - REAR ACCESS PANEL  
5/16" Nut  
REAR  
ACCESS  
PANEL  
Lead 118  
4
L2  
208V  
L1  
230V  
FIGURE F.21. - REAR ACCESS PANEL (CLOSE-UP)  
POWER MIG 200  
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F-46  
F-46  
NOTES  
POWER MIG 200  
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F-47  
F-47  
TROUBLESHOOTING AND REPAIR  
FAN BLADE/MOTOR REPLACEMENT  
WARNING  
Service and repair should only be performed by Lincoln Electric factory trained  
personnel. Unauthorized repairs performed on this equipment may result in  
danger to the technician or machine operator and will invalidate your factory  
warranty. For your safety and to avoid electrical shock please observe all safety  
notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the fan blade and fan motor  
for repair or replacement.  
MATERIALS NEEDED  
3/8” Nutdriver  
5/16” Nutdriver  
11/32” Open-End Wrench  
Flathead Screwdriver  
This procedure takes approximately 45 minutes to perform.  
POWER MIG 200  
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F-48  
F-48  
TROUBLESHOOTING AND REPAIR  
FAN BLADE/MOTOR REPLACEMENT (Continued)  
PROCEDURE  
8. Replace the fan motor and fan blade if nec-  
essary.  
1. Using a 3/8” nutdriver, remove the lower  
right side of the case wraparound cover.  
9. Tighten the fan blade mounting band.  
2. Perform the Output Capacitor Bank  
Removal Procedure.  
10. Carefully manuver the fan assembly into its  
original position.  
3. Using a 5/16” nutdriver, remove the four fan  
mounting screws from the rear of the  
machine. See Figure F.22.  
11. Replace the two 11/32” fan motor mounting  
nuts and lockwashers.  
4. Using an open end 11/32” wrench, remove  
the two fan motor mounting nuts and lock-  
washers. See Figure F.22.  
12. Replace the four 5/16” fan assembly mount-  
ing screws in the rear of the machine.  
NOTE: Make sure the fan blade is free to rotate  
when all of the mounting bolts are  
replaced.  
5. Using a flathead screwdriver, loosen the fan  
blade mounting band. See Figure F.22.  
6. Pry the fan blade off of the mounting shaft.  
NOTE: If fan blade cracks or breaks  
upon removal, replace it.  
13. Perform the Output Capacitor Bank  
Replacement Procedure.  
14. Replace the lower right case cover.  
7. Carefully manuver the fan motor and fan  
blade out of the right side of the machine.  
FIGURE F.22. - FAN MOUNTING BOLTS  
REAR  
Fan  
Blade  
Fan  
Motor  
Fan  
Mounting  
Band  
11/32"  
Mounting  
Nuts  
5/16" Bolts  
POWER MIG 200  
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F-49  
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.  
If for any reason you do not understand the test procedures or are unable to  
perform the test/repairs safely, contact the Lincoln Electric service department  
for technical troubleshooting assistance before you proceed. Call 1-800-833-  
9353(WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the output contactor for repair  
or replacement.  
MATERIALS NEEDED  
7/16” Wrench  
5/16” Nutdriver  
This procedure takes approximately 40 minutes to perform.  
POWER MIG 200  
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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  
8. Using a 7/16” wrench, mount the new output  
screws securing the tool tray.  
contactor in its proper location.  
2. Locate the output contactor. See Figure  
F.23.  
9. Reconnect leads 106B, 106C, & 107A to  
their proper terminals. See Wiring Diagram.  
3. Using a 7/16” wrench, label and remove the  
two thick black leads at the top of the output  
contactor. Note lead and washer placement  
for reassembly.  
10. Reconnect the two thick black leads previ-  
ously removed from the top of the output  
contactor.  
11. Replace the tool tray using a 5/16” nutdriv-  
4. Remove lead 107A and note lead place-  
ment. See Figure F.23.  
er.  
5. Remove leads 106B and 106C. See Figure  
F.23.  
6. Using a 7/16” wrench, remove the three  
mounting bolts from the output contactor.  
Note washer positions for replacement. See  
Figure F.24.  
FIGURE F.23. - OUTPUT CONTACTOR LEADS  
106B  
106C  
107A  
Output  
Contactor  
POWER MIG 200  
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F-51  
F-51  
TROUBLESHOOTING AND REPAIR  
OUTPUT CONTACTOR REPLACEMENT (Continued)  
FIGURE F.24. - OUTPUT CONTACTOR MOUNTING BOLTS  
7/16" Mounting  
Bolts  
POWER MIG 200  
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F-52  
F-52  
TROUBLESHOOTING AND REPAIR  
RETEST AFTER REPAIR  
INPUT IDLE AMPS AND WATTS  
Input Volts/Herts  
230/60  
Maximum Idle Amps  
2.0  
Maximum Idle Watts  
150  
OPEN CIRCUIT VOLTAGE  
35 - 40 VDC  
WIRE SPEED RANGE  
50 - 700 IPM (1.27 - 17.8 m/minute)  
POWER MIG 200  
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G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
-ELECTRICAL DIAGRAMS SECTION-  
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G  
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
CONTROL PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
CONTROL PC BOARD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
G-2  
G-3  
G-4  
POWER MIG 200  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM -  
POWER MIG 200 (208/230V)  
GENERAL INFORMATION  
NOTES:  
N.A.  
WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF  
IMMEDIATE AND FUTURE APPLICATIONS.  
ELECTRICAL SYMBOLS PER E1537  
CONTROL BOARD  
CAVITY NUMBERING SEQUENCE  
COLOR CODE  
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.  
(COMPONENT SIDE OF P.C. BOARD)  
B -  
W -  
R -  
U -  
BLACK  
WHITE  
RED  
1
8
1
2
3
6
1
BLUE  
J1  
J2  
J3  
101A  
1
2
16  
9
4
INDICATES CONNECTOR CAVITY No.  
102A  
103A  
RECTIFIER  
ASSEMBLY  
TRANSFORMER  
THERMOSTAT  
THERMOSTAT  
3
** CAVITY  
104A  
104A  
105A  
106A  
104B  
104C  
4
5
6
7
8
NUMBERING SEQUENCE  
(NON-LEAD SIDE OF CONNECTOR)  
J4 (TRIGGER,  
TACHOMETER,  
MOTOR SIDE)  
107A  
108A  
1
4
3
6
1
PA  
J1  
103A  
R2  
4
5
8
109A  
110A  
111A  
9
10  
11  
12  
13  
109A  
113A  
112A  
113A  
WIRE FEED  
SPEED  
14  
15  
114A  
115A  
116A  
108A  
16  
X9  
X10  
114A  
106A  
J5  
PA  
116A  
BAFFLE  
**  
MOUNTED  
RECTIFIER  
DIODE  
1
2
1
2
116B  
104C  
105A  
106C  
GAS  
SOLENOID  
BRIDGE  
X10  
3
4
5
6
3
4
5
6
116B  
106C  
27.8V  
107A  
106B  
104D  
105B  
106B  
X9  
X8  
X7  
X6  
X5  
X4  
X3  
X2  
X1  
G
F
JUMPER PLUG  
INSTALLED FOR  
NON-SPOOL GUN  
OPERATION  
H1  
H5  
L2  
L1  
SINGLE PHASE  
BRIDGE  
RECTIFIER  
GUN  
E
D
C
B
A
J4  
TRIGGER  
**  
H3  
H4  
H2  
L1  
L2  
1
1
104D  
111A  
115A  
101A  
102A  
324  
325  
R
TO SINGLE PHASE  
SUPPLY LINE  
2
3
4
CONTACTOR  
2
3
4
H2  
208V  
230V  
H1  
H4  
W
B
U
B
5
6
7
8
TAP SELECTOR  
SWITCH  
H1  
RECONNECT  
PANEL  
H3  
B
105B  
112A  
LINE  
SWITCH  
S1  
G
POWER  
W
TRANSFORMER  
TO GROUND PER  
NATIONAL ELECTRICAL  
CODE  
1
2
3
J2  
4
5
6
B
+
MOTOR/  
GEARBOX  
P.M.  
-
H1B  
H5  
R
U
B
T
A
C
H
FAN  
MOTOR  
TO  
WORK  
W
1
2
J3  
40 OHMS  
50 W  
C1  
C2  
C1 AND C2  
31,000 MFD  
50V  
+
+
OUTPUT  
CHOKE  
10-10-2000  
L11424  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
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G-3  
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.  
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G-4  
G-4  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY-CONTROL  
ITEM  
REQ’D PART No.  
G3851-B  
.01 oz. E3539  
DESCRIPTION  
ITEM  
REQ’D PART No.  
DESCRIPTION  
1
2
1
P.C. BOARD BLANK  
FOR ITEMS BELOW, REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS  
ELECTRICAL INSULATION COMPOUND  
R16,R17,R27,R70,R118  
5
2
7
4
1
1
4
7
2
2
1
4
2
2
1
3
2
1
2
1
1
2
1
1
1
1
1
3
1
2
3
2
1
1
1
2
3
2
1
1
1
2
1
1
1
1
2
1
1
1
2
1
1
1
1
1
S25000-1212SMT  
S25000-1000SMT  
S25000-1502SMT  
S25000-1002SMT  
S25000-6191SMT  
S25000-2211SMT  
S25000-8252SMT  
S25000-2002SMT  
S25000-2670SMT  
S18380-14  
RESISTOR,SMD,METAL FILM,1/10W,12.1K,1  
RESISTOR,SMD,METAL FILM,1/10W,100OHMS  
RESISTOR,SMD,METAL FILM,1/10W,15.0K,1  
RESISTOR,SMD,METAL FILM,1/10W,10.0K,1  
RESISTOR,SMD,METAL FILM,1/10W,6.19K,1  
RESISTOR,SMD,METAL FILM,1/10W,2.21K,1  
RESISTOR,SMD,METAL FILM,1/10W,82.5K,1  
RESISTOR,SMD,METAL FILM,1/10W,20.0K,1  
RESISTOR,SMD,METAL FILM,1/10W,267OHMS  
THERMISTOR,PTC,500OHMS,28mA  
FOR ITEMS BELOW, REFER TO ELECTRONIC COMPONENT DATABASE FOR COMPONENT SPECIFICATIONS  
R18,R75  
C1  
1
1
S13490-179  
CAPACITOR,ALEL,1000,35V,20%  
R19,R34,R61,R110,R111,R119,R123  
C2  
S25020-5SMT  
S13490-182  
CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X  
CAP,ALEL,3300,63V,20%  
R20,R32,R73,R127  
C3  
1
R22  
C4  
1
S25020-10SMT  
S25024-5SMT  
S25020-4SMT  
S25020-3SMT  
CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,  
CAPACITOR,SMD,TANTALUM,4.7MF,35V,10%,  
CAPACITOR,SMD,CERAMIC,820pF,50V,5%,CO  
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X  
R23  
C5  
1
R28,R29,R50,R51  
C6,C39,C48  
3
R30,R47,R88,R96,R97,R116,R124  
C7,C9,C11,C14,C15,C17,C18  
26  
R31,R35  
R37,R45  
R38  
C19,C22,C24,C27,C28,C29  
C32,C34,C35,C37,C38,C40  
S25000-6813SMT  
S25000-2210SMT  
S25001-3321SMT  
S25000-1003SMT  
S25000-3570SMT  
S25000-5111SMT  
S25004-2430SMT  
S25000-4751SMT  
S25000-3922SMT  
S25056-2SMT  
RESISTOR,SMD,METAL FILM,1/10W,681K,1%  
RESISTOR,SMD,METAL FILM,1/10W,221OHMS  
RESISTOR,SMD,3.32K,1/4W,1206,1%,TR  
RESISTOR,SMD,METAL FILM,1/10W,100K,1%  
RESISTOR,SMD,METAL FILM,1/10W,357OHMS  
RESISTOR,SMD,METAL FILM,1/10W,5.11K,1  
RESISTOR,SMD,1W,243OHMS,1%  
C41,C44,C47,C50,C52,C53,C54  
R39,R63,R79,R90  
R41,R64  
R42,R122  
R44  
C8  
1
1
6
2
2
2
1
1
1
1
6
5
1
3
1
3
1
1
1
2
2
1
1
1
2
1
12  
S25024-2SMT  
S25020-12SMT  
S25020-2SMT  
S25020-14SMT  
S25024-10SMT  
S25020-7SMT  
S25020-6SMT  
S25024-6SMT  
S25024-8SMT  
S25024-3SMT  
S25040-11SMT  
S25049-4SMT  
S25049-2SMT  
S25040-1SMT  
S25040-9SMT  
S25040-4SMT  
S25044-2SMT  
S25045-1SMT  
S25044-1SMT  
S25046-1SMT  
T12702-26  
CAPACITOR,SMD,TANTALUM,1.0MF,35V,10%,  
CAPACITOR,SMD,CERAMIC,100pF,100V,5%,C  
CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%  
CAPACITOR,SMD,CERAMIC,330pF,100V,5%,C  
CAPACITOR,SMD,TANTALUM,22MF,25V,10%,S  
CAPACITOR,SMD,CERAMIC,0.22MF,50V,20%,  
CAPACITOR,SMD,CERAMIC,4700pF,50V,5%,C  
CAPACITOR,SMD,TANTALUM,22MF,16V,10%,S  
CAPACITOR,SMD,TANTALUM,10MF,16V,10%,S  
CAPACITOR,SMD,TANTALUM,2.2MF,20V,10%,  
DIODE,SMD,1A,600V,S403A,ULTRA-FAST RE  
DIODE,SMD,DUAL,200MA,30V,SCHOTTKY,SOT  
DIODE,SMD,1A,30V,SMA,SCHOTTKY  
C10  
N.C. C12,C23,C30,C31,C36,C42,C43  
C13,C16  
R46,R80,R115  
R48,R49  
R52  
C20,C21  
POWER MIG 200  
CONTROL  
3. 30  
C25,C26  
RESISTOR,SMD,METAL FILM,1/10W,4.75K,1  
RESISTOR,SMD,METAL FILM,1/10W,39.2K,1  
TRIMMER,SMD,MT,1/4W,2K,10% ,LINEAR  
RESISTOR,SMD,12.1K,1/4W,1206,1%  
C2 1 C2 0  
R1 1  
DZ8  
DZ9  
G3851-1  
D1  
R32  
X3  
C33  
R25  
C1 1  
R53,R108  
R54  
C47  
R1 3  
C45  
3. 10  
C46  
R56  
S25001-1212SMT  
S25001-2672SMT  
S25000-9091SMT  
S25000-2431SMT  
S25000-3320SMT  
S25000-2432SMT  
S25000-3741SMT  
S25000-1001SMT  
S25000-1782SMT  
S25000-8251SMT  
S25000-6190SMT  
S25001-5621SMT  
S25005-1SMT  
R2  
X1  
C3 3  
C49  
C2  
R1  
R58,R81  
R59  
RESISTOR,SMD,26.7K,1/4W,1206,1%,TR  
RESISTOR,SMD,METAL FILM,1/10W,9.09K,1  
RESISTOR,SMD,METAL FILM,1/10W,2.43K,1  
RESISTOR,SMD,METAL FILM,1/10W,332OHMS  
RESISTOR,SMD,METAL FILM,1/10W,24.3K,1  
RESISTOR,SMD,METAL FILM,1/10W,3.74K,1  
RESISTOR,SMD,METAL FILM,1/10W,1.00K,1  
RESISTOR,SMD,METAL FILM,1/10W,17.8K,1  
RESISTOR,SMD,METAL FILM,1/10W,8.25K,1  
RESISTOR,SMD,METAL FILM,1/10W,619OHMS  
RESISTOR,SMD,5.62K,1/4W,1206,1%,TR  
RESISTOR,SMD,METAL STRIP,3W,0.05OHMS,  
RESISTOR,SMD,22.1K,1/4W,1206,1%  
R6 5  
C2 8  
R7 1  
R1 4 R24  
C12  
D1,D2,D3,D4,D5,D16  
TP  
TP1  
2
3
D6,D9,D10,D14,D17  
R60  
R5 0  
C23  
D7  
R62  
D8,D11,D13  
DIODE,SMD,1A,400V,FAST RECOVERY,DO-21  
DIODE,SMD,3A,200V,D0-214AB,ULTRA-FAST  
DIODE,SMD,DUAL,0.200A,70V,UFR  
R66  
R8 7  
R2 6  
C1 5  
TP1  
2
R1 13  
D12  
C3 4  
R27  
R68  
R1 08  
Q4  
R2 9  
D15,D18,D19  
R71,R87,R106  
R74  
R51  
C2 2  
R6 6  
DZ1  
ZENER DIODE,SMD,3W,8.2V,5%, SMB  
DZ4  
ZENER_DIODE,SMD,225mW,12V,5% ,SOT-23  
ZENER DIODE,SMD,3W,5.1V,5%, SMB  
D10  
R3 1  
R76,R100  
R77,R78,R89  
R82,R85  
R83  
TP1  
0
C42  
C5 3  
DZ5  
R8  
C3 6  
R76  
R4 4  
Q7  
C17  
D7  
C52  
DZ6,DZ7  
ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123  
ZENER DIODE, 1W,27V,10% 1N4750A  
Q6  
R57  
Q10  
DZ8,DZ9  
TP1  
C7  
R1 10  
J1  
S24020-16  
CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN  
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN  
CONNECTOR,MOLEX,MINI,PCB,2-PIN,TIN  
TRANSISTOR,SMD,NMF,T263,45A,100V(SS)  
TRANSISTOR,SMD,NMF,SOT-23,0.115A,60V,  
TRANSISTOR,SMD,NPN,0.5A,40V,SOT-23,MM  
4
R84  
S25001-2212SMT  
S25000-5622SMT  
S25000-2000SMT  
S25000-1821SMT  
S25000-6811SMT  
S25000-4750SMT  
S25001-1502SMT  
S25001-1001SMT  
S25001-6191SMT  
S25056-3SMT  
C4 3  
J2  
S24020-6  
R86  
RESISTOR,SMD,METAL FILM,1/10W,56.2K,1  
RESISTOR,SMD,METAL FILM,1/10W,200OHMS  
RESISTOR,SMD,METAL FILM,1/10W,1.82K,1  
RESISTOR,SMD,METAL FILM,1/10W,6.81K,1  
RESISTOR,SMD,METAL FILM,1/10W,475OHMS  
RESISTOR,SMD,15K,1/4W,1206,1% ,TR  
R75  
R5 4  
J3  
S24020-2  
R3 4  
R91,R102  
R92,R114,R117  
R93,R99  
R95  
R9 2 Q14  
TP  
Q1,Q9  
T12704-88SMT  
S25051-4SMT  
S25050-1SMT  
4
Q2  
R4  
R19  
C5 4  
R6  
D4  
Q3,Q4,Q5,Q6,Q7,Q11,Q13,Q14  
Q15,Q16,Q17,Q19  
Q8,Q10,Q12,Q18  
R1,R55  
R1 14  
R1 17 R95  
R5 5  
R101  
R5 6  
4
2
1
3
1
4
3
1
4
1
3
1
4
3
2
S25050-2SMT  
TRANSISTOR,SMS,PNP,SOT23,0.5A, 40V,MM  
RESISTOR,SMD,METAL FILM,1/10W,2.80K,1  
RESISTOR,SMD,METAL FILM,1/10W,31.6K,1  
RESISTOR,SMD,2.67K,1/4W,1206,1%,TR  
RESISTOR,SMD,24.9OHMS,1/4W,1206,1% ,TR  
RESISTOR,SMD,METAL FILM,1/10W,5.62K,1  
RESISTOR,SMD,METAL FILM,1/10W,33.2K,1  
RESISTOR,SMD,2K,1/4W,1206,1%,TR  
D17  
R103  
RESISTOR,SMD,1K,1/4W,1206,1%,TR  
D14  
R8 0  
X2  
R1 26  
R3  
R9 0  
S25000-2801SMT  
S25000-3162SMT  
S25001-2671SMT  
S25001-24R9SMT  
S25000-5621SMT  
S25000-3322SMT  
S25001-2001SMT  
S25001-1000SMT  
S25001-15R0SMT  
S25000-1652SMT  
S25000-6812SMT  
S25000-3321SMT  
S25001-1004SMT  
S25000-4753SMT  
R104,R107  
R109  
RESISTOR,SMD,6.19K,1/4W,1206,1%,TR  
TRIMMER,SMD,MT,1/4W,50K,10%,LINEAR  
RESISTOR,SMD,METAL FILM,1/10W,681OHMS  
RESISTOR,SMD,METAL FILM,1/10W,22.1K,1  
RESISTOR,SMD,METAL FILM,1/10W,750OHMS  
RESISTOR,SMD,249OHMS,1/4W,1206,1% ,TR  
TRANSFORMER,PCB,PWM,FLYBACK  
D3  
R2  
TP  
R3,R7,R126  
R4  
C27  
R112  
S25000-6810SMT  
S25000-2212SMT  
S25000-7500SMT  
S25001-2490SMT  
S20375-8  
D1 5  
C8  
5
Q9  
Q1  
R113  
R5,R33,R36,R120  
R6,R26,R121  
R8  
R125  
R128,R129  
T1  
R6 2  
C9  
R1 27 R23  
R6 0  
R1 07  
R9,R21,R40,R105  
R10  
RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR  
RESISTOR,SMD,15.0OHMS,1/4W,1206,1% ,TR  
RESISTOR,SMD,METAL FILM,1/10W,16.5K,1  
RESISTOR,SMD,METAL FILM,1/10W,68.1K,1  
RESISTOR,SMD,METAL FILM,1/10W,3.32K,1  
RESISTOR,SMD,1.00M,1/4W,1206,1%,TR  
RESISTOR,SMD,METAL FILM,1/10W,475K,1%  
X1  
S25068-11SMT  
S23060-1SMT  
IC,SMD,VOLTAGE REGULATOR,STEP-DOWN,AD  
IC,SMD,SWITCH,LO-SIDE,2.2A,60V,SOT-22  
IC,SMT,COMPARATOR,QUAD,2901D  
R63  
X2  
C46  
R101  
R99  
D2  
R11,R72,R94  
R12  
X3,X9  
S15128-11SMT  
S25067-1SMT  
X4  
IC,BIPOLAR,TIMER,SOIC-14  
R22  
C1 0  
R46  
R4 8  
R3 7  
R13,R25,R43,R98  
R14,R24,R57  
R15,R65  
X5  
S25068-2SMT  
IC,SMT,CMOS,DRIVER,MOSFET,2113(SS)  
IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074D  
IC,CONVERTER,F/V ,2907, SO-8  
R4 5  
X6  
S15128-18SMT  
M13552-2SMT  
C49  
X7  
X8  
S15128-4SMT  
OP-AMP,SMD,QUAD, GEN-PURPOSE,224D  
UNLESS OTHERWISE SPECIFIED:  
CAPACITANCE = MFD/VOLTS  
INDUCTANCE = HENRIES  
RESISTANCE = OHMS  
R1 22  
Q12  
R4 7  
R6 1  
D16  
R4 9  
.20  
0
J1  
J3  
J2  
R1 24  
R8 3  
0 .20  
5. 60 5.80  
THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHO UT THE EXPRESS WRI TTEN PERMI SSI ON OF THE LI NCO LN ELECTRI C COMPANY, CLEVELAND, O HI O U.S. A.  
UNLESS OTHERWISE SPECIFIEDTOLERANCE  
"X" INFO.  
XA  
Chg. Sheet No.  
10-20-2000  
DESIGN INFORMATION  
DRAWN BY:  
REFERENCE:  
MANUF ACT URI NG TO LERANCE PERE2056  
EQUIPMENT TYPE:  
ON  
ON  
2
3
P LACE DECIM ALS IS ± .0 2  
L11110-1  
PLACE DECIMALS IS ± .002  
ON AL L ANGL ES IS ± .5 OF  
A
DEGREE  
SUBJECT:  
SUPERSEDING:  
MATERIAL TOLERANCE ("  
WITH PUBLISHED STANDARDS.  
t
") TO AGREE  
ENGINEER:  
APPROVED:  
SCALE:  
DATE:  
DRAWING No.:  
3851-1  
DO NOT SCALE THIS DRAWING  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SVM ERROR REPORTING FORM  
We need to know if there are errors in our manuals. We also value any suggestions as to  
additional tests or procedures that would make this SVM a better tool for you.  
If you discover new or different “Problems or Symptoms” that are not covered in the three col-  
umn troubleshooting chart, please share this information with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 ST. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
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