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Lincoln Electric POWER MIG 211i, Operator'S Manual, Page: 22 / 28

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23

TROUBLE SHOOTING

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local  Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

PROBLEMS

(SYMPTOMS)

POSSIBLE 

CAUSE

RECOMMENDED

COURSE OF ACTION

Arc is unstable - Poor starting.

1. Check for correct input voltage

to machine.

2. Check  for  proper  electrode

polarity for process.

3. Check  gun  tip  for  wear  or

damage  and  proper  size  -

Replace.

4. Check for proper gas and flow

rate  for  process.  (For  MIG

only.)

5. Check work cable for loose or

faulty connections.

6. Check  gun  for  damage  or

breaks.

7. Check for proper drive roll ori-

entation and alignment.

8. Check liner for proper size.

If all recommended possible areas of

misadjustment have been checked

and the problem persists, 

Contact

your local Lincoln Authorized
Field Service Facility.

CAUTION

POWER MIG   211i

® 

Summary of Contents for POWER MIG 211i

Page 1: ...horized Service and Distributor Locator www lincolnelectric com locator IM10644 Issue Date Apr 22 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 13214 Save for future reference Date Purchased Code ex 10859 Serial ex U1060512345 POWER MIG 211 i ...

Page 2: ...N A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted...

Page 3: ... belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan ...

Page 4: ...m 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 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 FUMES AND GASES CAN BE DANGEROUS 5 a Welding may produce fumes an...

Page 5: ...ent passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy MA 022690 9101 6 j Do not use a welding power source for pipe...

Page 6: ...y Information 14 Input and Ground Connections 14 Location and Mounting 14 High Frequency Protection 14 Connection Diagram s System 15 Electrode and Work Connections 16 Operation 17 Graphic Symbols 17 Power Up Sequence 17 Duty Cycle General Options and Accessories Drive Roll Kits Maintenance Routine Maintenance General Maintenance Periodic Maintenance Troubleshooting How to Use Troubleshooting Guid...

Page 7: ...MIG 211iis designed for the North American market and operates on 120 or 230 single phase 60 Hz power An overview of the machines input and output capabilities are listed on the rating plate shown at right The Power MIG 211i is Magnum Pro 100SG spool gun ready the spool gun switch is preinstalled from the factory and an option is present on the user interface which permits activating the spool gun...

Page 8: ...t of the machine is limited when the machine is connected to 120VAC input details regarding the rating when the machine is connected to 120VAC can be seen on the rating plate Locate the welder in a dry location with free circulation of clean air into the back A location that minimizes the amount of smoke and dirt drawn into the rear louvers will reduces the probability of dirt accumulating and blo...

Page 9: ...Cord and Fuse Sizes based upon the U S National Electric Code and maximum output DUTY CYCLE OUTPUT INPUT VOLTAGE INPUT AMPERES MAX IDLE AMPS 30 5A 22 V 230 22 5A A 60 95A V 120 20A A POWER MIG 211i ENGINE DRIVEN GENERATOR The machine is designed to operate on engine driven generators as long as the auxiliary can supply adequate voltage frequency and power as indicated in the Technical Specificatio...

Page 10: ...Factor The Power MIG 211i features active power factor correction 98 which reduces the unit s current draw 120 or 230V Capable Easily connect the unit to 120V or for higher loads connect to 230V The unit includes a hardwired 230V cord and a 120V to 230V input adapter for easily switching between the two input voltages Portability The unit features three handles for carrying in multiple orientation...

Page 11: ...Wire Drive Polarity Lead Permits configuring the wire drive to positive or negative polarity by inserting into the positive or negative stud Ensure connector is tightly locked into place by rotating clockwise 10 Positive Output Receptacle Permits attaching a work lead electrode stinger or the center wire drive polarity lead to DC positive polarity Rotate clockwise to lock into place 11 Negative Ou...

Page 12: ...ter The outer wire guide provided can be used for any wire diameter 5 Replaceable drive roll Select the correct drive roll for the wire diameter and composition being fed 6 Gun Connector Block Permits securing a welding gun to the wire drive by ensuring the gun connector is fully seated then tightening the large knob FIGURE A 2 FIGURE A 3 1 2 6 4 5 3 1 MIG Gas Solenoid Connector Connection for the...

Page 13: ...wo 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 inserted into a grounded receptacle CONNECT TO A SYSTEM GROUNDING WIRE SEE THE UNITED STATES NATIONAL E...

Page 14: ...an Welding Society Install shielding gas supply as follows sturdy structure to prevent the cylinder from falling over 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 DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the pre...

Page 15: ...m down toward the back of the machine Lift the cast idle roll assembly and allow it to sit in an upright position 3 Remove the outside wire guide retaining plate by loosening the two large knurled screws 4 Twist the drive roll retaining mechanism to the unlocked position as shown below and remove the drive roll 5 Remove the inside wire guide plate 6 Replace the drive roll and inside wire guide wit...

Page 16: ...he interface will determine the best settings for the selected input values 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 from the end of the contact tip 4 If shielding gas is to be used turn on the gas supply and set the required flow rate typically 25 35 CFH 12 16 liters min 5 When using an Innershield electrode...

Page 17: ...ED OVERLOAD PROTECTION The Power MIG 211i features overload protection of the wire drive motor If the motor becomes overloaded the protection circuitry turns off the wire feed unit Check for the 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 b...

Page 18: ...apered Contact Tip KP2744 035T 045 Magnum Pro Tapered Contact Tip KP2744 045T 025 035 Gun Liner KP35 40 15 035 to 045 Gun Liner KP45 40 15 Magnum Pro 100L Gun K4528 1 Magnum Pro 100SG Spool Gun K3269 1 Magnum Pro Gas Nozzle KP3075 1 38F Magnum Pro Flux Gasless Nozzle KP3084 1 025 030 Drive Roll MIG KP2529 1 035 Drive Roll MIG KP2529 2 030 045 Drive Roll Flux Cored KP2529 3 Welding Cart K520 ...

Page 19: ...er 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 replace the liner PERIODIC MAINTENANCE LINER REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM PRO 100L NOTE The variation in cable lengths prevents interchanging of liners between guns Once a liner has been cut for a particular gun...

Page 20: ...OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the test procedures or are unable to perform the tes...

Page 21: ... or turn it on Contact your local Authorized Field Service Facility 1 Make sure correct voltage is applied to the machine 2 Make certain that power switch is in the ON position 3 Make sure circuit breaker is reset 1 The thermostat may be tripped due to overheating Let machine cool Weld at lower duty cycle 2 Check for obstructions in air flow Check Gun Trigger connections See installation section 3...

Page 22: ...stable Poor starting 1 Check for correct input voltage to machine 2 Check for proper electrode polarity for process 3 Check gun tip for wear or damage and proper size Replace 4 Check for proper gas and flow rate for process For MIG only 5 Check work cable for loose or faulty connections 6 Check gun for damage or breaks 7 Check for proper drive roll ori entation and alignment 8 Check liner for prop...

Page 23: ...ARD T1 OUTPUT OUTPUT CHOKE MAIN TRANSFORMER RECTIFIER FANS GAS SOLENOID TO GROUND PER NATIONAL ELECTRICAL CODE S1 INPUT CORD J1 SPOOL GUN SWITCH GREEN WHITE BLACK AC3 AC4 1 7 4 3 2 1 CN304 CN303 CONTROL BOARD 5 6 7 8 9 10 11 12 13 14 4 3 2 1 CN305 20 CONDUCTOR RIBBON CABLE 4 3 2 1 303 302 304 301 302 303 304 301 BOOST COIL L1 2 L1 1 CN2 1 20 FERRITE 2 1 J4 401 408 L1 405 410 411 CIRCUIT BREAKER CB...

Page 24: ...25 DIAGRAMS POWER MIG 211i DIMENSION PRINT POWER MIG 211i 15 08 21 49 12 00 3 80 2 69 10 88 2 44 10 88 ...

Page 25: ...This page intentionally left blank ...

Page 26: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra l Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension l Isolez vous du travail et de la terre l Berühren Sie keine stromführenden Teile oder Elektroden mit ...

Page 27: ... und Entlüftung des Arbeitsplatzes l Mantenha seu rosto da fumaça l Use ventilação e exhaustão para remover fumo da zona respiratória l Turn power off before servicing l Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio l Débranchez le courant avant l entre tien l Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten l Não o...

Page 28: ...n or communications Moreover the provision of such information or technical information does not create expand or alter any warranty on our products Any express or implied warranty that might arise from the information or technical information including any implied warranty of merchantability or any warranty by Lincoln Electric is solely within the control of and remains the sole responsibility of...

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