Variations, Avoiding Wire Feeding, Problems

B-6

OPERATION

B-6

When no more

welding is to be done, close valve

INPUT LINE VOLTAGE

VARIATIONS

on gas cylinder (if used), momentarily operate gun

High Line Voltage — Higher than rated input voltage

trigger to release gas pressure, and turn off

will result in output voltages higher than normal for a

POWER MIG 215.

given tap setting. If your input line is high, you may

NOTE: When using Innershield electrode, the gas

want to select a lower voltage tap than given on the

recommended procedure chart.

nozzle may be removed from the insulation on

the end of the gun and replaced with the gas-

Low Line Voltage — You may not be able to get

less nozzle. This will give improved visibility

maximum output from the machine if the line voltage

and eliminate the possibility of the gas nozzle

is less than rated input. The unit will continue to weld,

overheating.

but the output may be less than normal for a given tap

AVOIDING WIRE FEEDING

a higher voltage tap than given on the recommended

PROBLEMS

setting. If your input line is low, you may want to select

procedure chart.

Wire feeding problems can be avoided by observing

WIRE FEED OVERLOAD

the following gun handling procedures:

1. Do not kink or pull cable around sharp corners.

PROTECTION

The POWER MIG has solid state overload protection

2. Keep the gun cable as straight as possible when

of the wire drive motor. If the motor becomes over-

welding or loading electrode through cable.

loaded, the protection circuitry turns off the wire feed

3. Do not allow dolly wheels or trucks to run over

speed and gas solenoid. Check for proper size tip,

cables.

liner, and drive rolls, for any obstructions or bends in

4. Keep cable clean by following maintenance instruc-

the gun cable, and any other factors that would

tions.

impede the wire feeding. to resume welding, simply

5. Use only clean, rust-free electrode. The Lincoln

pull the trigger. There is no circuit breaker to reset, as

electrodes have proper surface lubrication.

the protection is done with reliable solid state electron-

6. Replace contact tip when the arc starts to become

ics.

unstable or the contact tip end is fused or

deformed.

WELDING THERMAL OVERLOAD

7. Keep wire reel spindle brake tension to minimum

PROTECTION

required to prevent excess reel over-travel which

The POWER MIG 215 has built-in protective ther-

may cause wire “loop-offs” from coil.

mostats that respond to excessive temperature. They

8. Use proper drive rolls and wire drive idle roll pres-

open the wire feed and welder output circuits if the

sure for wire size and type being used.

machine exceeds the maximum safe operating tem-

FAN CONTROL

perature because of a frequent overload, or high

ambient temperature plus overload. The thermostats

The fan is designed to come on when input power is

automatically reset when the temperature reaches a

applied to the POWER MIG 215 and go off when

safe operating level and welding and feeding are

power is removed.

allowed again, when gun is retriggered.

PROCEDURE CHART

Wire Feed Speed/Voltage Tap Settings

Wire Dia.

Gas Type

Wire Type

Polarity

18 gage

16 gage14 gage

12 gage10gage

3/16

1/4

5/16

3/8

1/2

Outershield

1" CTWD†

OS71M

DC+

250/D

300/E

350/F

500/G

*500/G

.035

75Ar/25CO2

.035

100%CO

OS71M

DC+

300/E

350/F

500/G

250/G

*250/G

.045

75Ar/25CO2

OS71M

DC+

200/E

225/F

Innershield

5/8" CTWD†

NR-211MP

DC-

50/B

70/B

80/B

90/C

100/C

.035

NoneReqʼd

90/C

110/D

**130/E

.045

NoneReqʼd

NR-211MP

DC-

40/B

50/B

60/B

50/B

70/C

*150/E

.045

NoneReqʼd

NR212

DC-

65/C

70/C

90/C

110/D

*130/E

† Contact Tip

to Work Distance

* Note- Requires Multiple Pass

**.035 & .045 NR-211 MP are only recommended for a maximum steel thickness of 5/16"

POWER MIG 215