Lincoln Electric Power Mig 215 XT User manual

PO ER MIG®. The Professional’s ChoiceSM .
The POWER M G®215XT offers the autobody and sheet metal fabrication
industries top welding performance and a host of professional features
not often found at this price. Featuring Diamond Core Technology™, the
POWER M G®215XT delivers a forgiving arc, excellent out-of-position arc
action, a wide voltage sweet spot at a given wire feed speed and low spatter.
And, the MAXTRAC®drive system with a patented Split Wire Guide system
and tachometer feedback ensures trouble-free wire delivery. The wide
30-250 amp output range, standard 15 foot gun cable, and 115 volt auxiliary
power receptacle are uncommon in this class. n addition, the 7 voltage tap
ranges make it easy to operate and the locking storage compartment keeps
your valuable tools secure. The POWER M G®215XT is Spool Gun Ready for
Lincoln’s light duty Magnum®100SG Spool Gun. The POWER M G®215 XT—
truly The Professional’s ChoiceSM.
WIRE FEEDER/WELDERS
CV
DC
1
PHASE
Public tion E7.51 7/08
www.lincolnelectric.com
Advantage Lincoln
POWER MIG®215XT
Output
Input
(1) 21V on 220V 50 Hz input.
(2) Input current is at the rated output with the 115V auxiliary receptacle also drawing 15 amps.
Arc Performance:
•Diamond Core Technology™, a patented choke design, delivers a
forgiving arc, even with large stickout changes, excellent out-of-
position arc action, a wide voltage sweet spot at a given wire feed
speed for steel, stainless steel or aluminum and low spatter.
•More Output – Rated at 215 amps/22 volts @ 30% duty cycle, with
an amperage range of 30-250 amps DC, the POWER M G®215XT
has the highest rating and widest amperage range in its class.
Superb Quality:
•MAXTRAC®cast aluminum industrial wire drive features dual driven
rolls, regulated wire feed speed control, easy-turn numeric tension
indicator, brass-to-brass connections and Lincoln’s 100% wire
supporting split wire guide system.
•Three-year warranty on parts and labor (90 days warranty on gun).
Professional Features:
•Generous 15 ft. (4.5m) gun and cable assembly makes it easy to
reach your work.
•Seven tapped voltage ranges make it easy to select the right
procedure for your application.
•Only machine in its class to feature a 115 volt auxiliary power
receptacle.
•Lincoln’s Innovative value-adding features include an easy-load gas
cylinder platform, a locking storage compartment with tool tray for
your personal tools and valuables, intuitive input reconnect panel and
easy-load wire spindle system with tool-less brake adjustment.
TECHNICAL SPECIFICATIONS
Product
Name Product Number Input Power Rated Output Current/Voltage/Duty Cycle Input Current @
Rated Output(2) Output Range
Dimensions
H x x D
inches (mm) Net eight
lbs. (kg)
POWER M G®215XT K2700-1 208/230/1/50/60
215A / 22V(1) / 30%
190A / 23V / 40%
170A / 24V / 60%
45/41A
42/38A
39/35A
30-250 Amps DC
50-700 ipm WFS
(1.3-17.7 m/min)
Max. OCV: 39V
31.8 x 18.9 x 38.8
(808 x 408 x 985)
210
(95)
Spool Gun Capable
Light Duty Medium Duty Heavy Duty
Spool Gun Ready
Processes
M G, Flux-Cored

POWER MIG®215XT
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[2]
A CLOSER LOOK
PROCESS CAPABILITIES
Electrode Electrode Shielding Minimum Maximum
Process ire Polarity Gas Thickness Thickness(1)
MIG .025, .030, .035, .045"
Mild Steel (0.6, 0.8, 0.9, 1.2 mm) DC+ 100% CO2or Ar/CO2Blend 24 ga. (.024") 5/16" (.312")
SuperArc®L50, L-56 (0.6 mm) (7.9 mm)
SuperGlide®S-3, S-6
MIG .030, .035, .045" DC+ Ar/CO2Blend 20 ga. (.036") 1/4" (.250")
Stainless (0.8, 0.9, 1.2 mm) or (Tri-Mix) (0.9 mm) (6.4 mm)
Blue Max®308LSi, 309LSi, 316LSi 90% He, 7-8% Ar/Balance C02
MIG 3/64" 1/16" (.063") 1/4" (.250")
Aluminum(3) (0.2 mm) DC+ 100% Argon (1.6 mm) (6.4 mm)
SuperGlaze®4043 and 5356
Flux-Cored, .035, .045" 100% CO2or Ar/CO2Blend 12 ga. (.109") 1/2" (.500")
Gas-Shielded (0.9, 1.2 mm) DC+ (2.7 mm) (12.7 mm)
Mild Steel Outershield®71M and MC-710
Flux-Cored, .035, .045" 18 ga. (.050") 1/2" (.500")
Self-Shielded (0.9, 1.2 mm) DC- — (1.2 mm) (12.7 mm)
Mild Steel nnershield®NR®-211-MP(2) and NR®-212
(1) Lincoln Electric recommends multiple pass welds on 1/2" (12.7 mm) material. Consult the appropriate application procedures and guidelines for selecting the correct wire size,
gas type and number of passes.
(2) .035" and .045" (0.9 and 1.2 mm) NR®-211-MP is only recommended up to 5/16" (7.9 mm) thick material.
(3) For .035" (0.9 mm) and 4043 aluminum wire, the spool gun is recommended for best feeding results.
FEATURES
En rgiz Your Shop
The POWER MIG®215XT is the only
machine in its class to feature a 115 volt
auxiliary power receptacle which allows
you to power grinders, lights, cordless
tool chargers or any other power tools.
PERFORMANCE
Grinders
B ttery Ch rgers
for Cordless Tools
Work Lights
Welding Fume
Extr ction
Rot ry Tools
S ws
What Is It?
Diamond Core Technology™is a patented innovative
choke design that filters the welding arc. It provides
dynamic arc filtering across the entire welding amp
rage. Other arc stabilization methods are “fixed” –
or only working at certain amperages – resulting in
harsh arc characteristic changes over the welding
range.
Results:
• Great starts and low spatter.
• A wide sweet spot for optimal
arc performance.
Great For:
• Steel, stainless and aluminum.
• Out-of-position work.
• ong arc applications.
• Weaving techniques.

POWER MIG®215XT
www.lincolnelectric.com
[3]
A CLOSER LOOK
FEATURES CONʼT.
Split guides support the wire
through the entire drive system
to minimize feeding problems.
Wide idler rm hinge provides
improved drive roll cl mping
pressure.
Remov ble outer wire guide
for e sy ccess.
Input bushing protects the
wire from d m ge.
Reli ble br ss-to-br ss gun receiver
bushings provide connectivity to
M gnum®or competitive guns. E sier
interch nge bility, better mech nic l
support nd electric l current tr nsfer.
E sy turn numeric tension
indic tor with optimized
r nges for different wire types.
Intern l feedb ck drive system
llows you to m int in
const nt wire feed speed
for consistent welds.
Sep r te drive ge r reduces
pressure on motor sh ft for
long life.
Two ge r driven rolls. No tools needed
to sw p rolls on or off.
Professional Heavy Duty Wire Drive System
Convenient oper ting procedures for
MIG welding on mild steel, luminum
nd st inless, loc ted inside the
POWER MIG®215XT door.
Compare These Innovations – Make the Professional’s ChoiceSM!
Extr -Length 15 ft. (4.5 m) GunBuilt-in underc rri ge with E sy
Lo d G s Cylinder Pl tform
E sy Lo d Wire Comp rtment
Lock ble stor ge comp rtment
with tool tr y stows your welding
consum bles nd v lu ble
person l tools.
Angled gun c ble connection
for improved feed bility nd
reduced gun liner we r.

POWER MIG®215XT
www.lincolnelectric.com
[4]
A CLOSER LOOK
QUALITY AND RELIABILITY
• Thermostatic protection from current overload and excessive
temperatures.
• Clear reconnect door permits easy viewing of input voltage.
• ow input current draw for energy-efficient low cost operation.
• Fan-As-Needed™(F.A.N.™) provides cooling of transformer and
other components when welding, reducing power consumption,
noise and extending welder life.
• Manufactured under a quality system certified to ISO 9001
requirements and ISO 14001 environmental standards.
• Three-year warranty on parts and labor. 90 days warranty on gun
and cable.
Key Controls
A. Wide range wire feed speed (WFS) control up to 700 inches per
minute (17.7 m/min). Dial calibrated in true inches per minute for
easy procedure setting.
B. Seven voltage taps for wide range voltage control. A
B
The POWER MIG®215XT is n excellent choice for sheet met l job
shop f bric tion, utobody work nd m inten nce/rep ir welding.
Printed circuit bo rds re environment lly-shielded using
Lincolnʼs engineered potting nd protective fr me tr ys.

POWER MIG®215XT
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[5]
SYSTEM SELECTION
WHATʼS INCLUDED
K2700-1 Includes:
• POWER MIG®215XT.
• Magnum®250 gun and 15 ft. (4.5 m) “quick-connect” cable assembly
equipped with fixed gas nozzle assembly.
• ockable storage compartment with tool tray for keeping tools safe.
• Work clamp and 10 ft. (3.0 m) cable.
• 10 ft. (3.0 m) 230V input power cable with plug.
• Dual driven drive rolls and split wire guides to support the wire 100%.
• Drive roll and wire guide to feed both .035" &.045" (0.9 &1.2 mm) wire.
• Gas regulator and hose kit for CO2or argon blend gases. (For use with
CO2shielding gas, order a incoln S19298 CO2shielding gas bottle
adapter.)
SPOOL GUN SOLUTIONS
Spool Guns offer an affordable way to reliably feed soft aluminum wire. Since spool guns feed small 4 inch spools of wire a short
distance it provides a reliable feeding solution that prevents wire jams and tangles. The POWER MIG®215XT provides three choices
of spool gun solutions form the cost effective light duty Magnum®100SG for occasional aluminum projects to the premium heavy
duty Magnum®250 X which is designed for day in day out aluminum welding applications.
LIGHT DUTY MEDIUM DUTY HEAVY DUTY
Magnum®100 SG Spool Gun
(K2532-1)
Magnum®SG Spool Gun
(K487-25)
Magnum®250LX Spool Gun
(K2490-1)
• 130 Amp 30% Duty Cycle
• 10 ft. cable length
• Feeds .030 - .035 in. diameter wire
• Wire Feed Speed is set at machine
• Fixed wire spool brake with friction
pads for 5356 wire
• Fixed drive roll tension
• 250 Amp 60% Duty Cycle
• 25 ft. cable length
• Feeds .025 - 3/64 in. diameter wire
• Single Turn remote Wire feed speed
control at the gun
• Adjustable wire spool brake
• Adjustable drive roll tension
• 300 Amp 60% Duty Cycle
• 25 ft. cable length
• Feeds .025 - 3/64 in. diameter wire
• Multi-Turn remote Wire feed speed
control at the gun
• Deluxe wire spool break requires
no adjustments
• Adjustable drive roll tension
• Ergonomic Sure Grip handle
• Contact tip storage built in spool
gun cover
• Easy open wire drive rolls for easy
wire loading
Factory Ready!
No Adapter Required! Requires K2703-1 Adapter Requires K2703-1 Adapter

Industry
Description Order No. Reference No.
Magnum®250L Gun and Cable Assembly
Fixed Gas Nozzle Model
For .035-.045" (0.9-1.2 mm) wire sizes
12 ft. (3.6 m) cable K533-7
Adjustable Gas Nozzle Model
For .035-.045" (0.9-1.2 mm) wire sizes
10 ft. (3.0 m) cable K533-1
15 ft. (4.5 m) cable K533-3
Cable Liners
For All Gun Cable Lengths
.025-.030" (0.6-0.8 mm) KP1934-2 42-23-15
.030-.035" (0.8-0.9 mm) KP1934-3 42-3035-15
.035-.045" (0.9-1.2 mm) KP1934-1(1) 42-4045-15
3/64" (1.2 mm) Aluminum KP1955-1(2) 42N-3545-15
Contact Tips
Standard Duty
.025" (0.6 mm) KP2020-6 14-23
.030" (0.8 mm) KP2020-7 14-30
.035" (0.9 mm) KP2020-1(1) 14-35
.040" (1.0 mm) KP2020-8 14-40
.045" (1.2 mm) KP2020-2 14-45
Heavy Duty
.035" (0.9 mm) KP2021-1 14H-35
.040" (1.0 mm) KP2021-6 14H-40
.045" (1.2 mm) KP2021-2 14H-45
Tapered
.025" (0.6 mm) KP2022-5 14T-23
.030" (0.8 mm) KP2022-6 14T-30
.035" (0.9 mm) KP2022-1 14T-35
.040" (1.0 mm) KP2022-7 14T-40
.045" (1.2 mm) KP2022-2 14T-45
Aluminum
3/64" (1.2 mm) KP2010-5(2)
POWER MIG®215XT
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[6]
A CLOSER LOOK
THE MAGNUM®250L GUN
• Magnum®250 gun and cable assembly, shipped with
the POWER MIG®215XT is equipped to feed .035"-.045"
(0.9-1.2 mm) solid steel wire.
• Extra reach 15 foot gun cable length.
• ightweight and flexible for easy maneuverability.
• Fiberglass handle with non-slip grooves to maximize comfort
and control.
• Heavy duty gun trigger switch for positive electrical contact
and long life.
• Magnum®replacement parts are fully compatible with other
leading brands. Industry reference numbers are provided for
ease of interchangeability.
(1) ncluded with POWER M G®215XT.
(2) ncluded in the K1703-1 Aluminum Feeding Kit.
MAGNUM®REPLACEMENT PARTS MAGNUM®REPLACEMENT PARTS
Industry
Description Order No. Reference No.
Fixed Gas Nozzles/Diffuser Assembly
Fixed (flush)
3/8" (9.5 mm) KP1931-1 23-37-F
1/2" (12.7 mm) KP1931-2(1) 23-50-F
5/8" (15.9 mm) KP1931-3 23-63-F
Fixed (recessed)
3/8" (9.5 mm) KP1930-1 23-37
1/2" (12.7 mm) KP1930-2 23-50
5/8" (15.9 mm) KP1930-3 23-62
Requires: Gas Diffuser Assembly
.025-.045" (0.6-1.2 mm) KP2026-3(1) 52FN
Adjustable Gas Nozzle/Diffuser Assembly
Adjustable Slip-On
3/8" (9.5 mm) KP1935-3 22-37
1/2" (12.7 mm) KP1935-2 22-50
5/8" (15.9 mm) KP1935-1 22-62
Requires:
Nozzle nsulator Assembly KP2025-1 32
Gas Diffuser Assembly:
.023-.030" (0.6-0.8 mm) KP2026-2 52-23
.035-.045” (0.9-1.2 mm) KP2026-1 52
Gasless Nozzle/Diffuser Assembly
( nnershield®Nozzle) KP1947-1
Requires:
Gas Diffuser Assembly KP2026-1 52
Gun Tube Assembly
Standard (60°) KP2015-1(1)
45° KP2041-1
ire Size Order Number
.023-.030” (0.6–0.8 mm) KP1696-030S
Solid .035" (0.9 mm) KP1696-035S
(1)
.035/.045" combination KP1696-1
.040" (1.0mm) KP1696-2
.045" (1.2 mm) KP1696-045S
Cored .035" (0.9 mm) KP1697-035C
.045" (1.2 mm) KP1697-045C
Aluminum 3/64" (1.2 mm) KP1695-3/64A
(2)
(1) ncluded with POWER M G®215XT.
(2) ncluded in the K1703-1 Aluminum Feeding Kit.
DRIVE ROLL KITS

POWER MIG®215XT
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[7]
RECOMMENDED OPTIONS
GENERAL OPTIONS
Magnum®Connection Kit
Permits use of Magnum®200, 300
and 400 gun and cable assemblies
on POWER MIG®215 XT.
Order K466-6
POWER MIG®215XT Spool
Gun Adapter
This kit is designed to allow the
Magnum®SG or Magnum®250 X
spool gun to operate with the
POWER MIG®215XT. The kit
includes the solenoid, gas lines,
wiring harness and gun connection
panel. The gun connection panel
features a 6 pin MS-type
connector for the Magnum®SG
spool gun and a 7 pin MS-type
connector for the Magnum®250 X
spool gun and a selector switch to
choose which gun you are using.
Order K2703-1
Note the K2703-1 spool gun
adapter disables the Magnum®
100SG capability.
Aluminum Feeding Kit
Conversion kit for welding with
3/64" (1.2 mm) 5356 aluminum
wire. Includes drive rolls,
contact tips (2), non-metallic wire
guides and cable liner.
Order K1703-1
Spindle Adapter for 8" O.D.
Spools
Permits 8" (200 mm) O.D. spools
to be mounted on 2" (51 mm) O.D.
spindles.
Order K468
Dual Cylinder Mounting Kit
Permits side-by-side mounting of
two full size gas cylinders, with
easy loading. Attaches easily to
POWER MIG®215XT
undercarriage.
Order K1702-1
Canvas Cover
Protect your POWER MIG®when
not in use. Made from attractive
red canvas that is flame retardant,
mildew resistant and water
repellent. Fits any POWER MIG®
machine with or without a gas
cylinder in the cylinder rack. Will
not fit if spool gun holder is
attached to the machine.
Order K2378-1
Welding Fume Extractors
incoln offers a wide variety
of welding fume extraction
environmental system solutions,
ranging from portable systems
easily wheeled around the shop
to shop-wide central systems
servicing many dedicated welding
stations.
Request Publication E13.40
Magnum®100SG Spool Gun
130 Amp, 30% Duty Cycle with 10
ft of cable length. Feeds .030-.035
inch diameter wire. Wire Feed
Speed is set at the machine. Fixed
wire spool brake with friction pads
for 5356 wire. Fixed drive roll
tension.
Order K2532-1
Factory Ready!
No Adapter Required!
Magnum®SG Spool Gun
250 Amp, 60% Duty Cycle with
25 ft. of cable length. Feeds
.025 - 3/64 inch diameter wire.
Single Turn remote wire feed
speed control at the gun.
Adjustable wire spool brake and
adjustable drive roll tension.
Order K487-25
Requires K2703-1 Adapter
Magnum®250LX Spool Gun
300 Amp, 60% Duty Cycle with
25 ft. of cable length. Feeds
.025 - 3/64 inch diameter wire.
Multi-Turn remote wire feed
speed control at the gun.
Deluxe wire spool break requires
no adjustments. Adjustable drive
roll tension and easy open wire
drive rolls for easy wire loading.
Ergonomic Sure Grip handle.
Contact tip storage built in
spool gun cover.
Order K2490-1
Requires K2703-1 Adapter

CUSTOMER ASSISTANCE POLICY
The business of The incoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the
needs of our customers and to exceed their expectations. On occasion, purchasers may ask incoln Electric®for advice or information about their use of our products. We respond
to our customers based on the best information in our possession at that time. incoln Electric®is not in a position to warrant or guarantee such advice, and assumes no liability,
with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to
such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has
been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.
incoln Electric®is a responsible manufacturer, but the selection and use of specific products sold by incoln Electric®is solely within the control of, and remains the sole responsibility
of the customer. Many variables beyond the control of incoln Electric®affect the results obtained in applying these types of fabrication methods and service requirements.
Subject to Change — This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
POWER MIG®215XT ORDER FORM
PRODUCT DESCRIPTION ORDER NUMBER QUANTITY PRICE
POWER MIG®215XT 208/230V K2700-1
RECOMMENDED GENERAL OPTIONS
Magnum®Connection Kit K466-6
POWER MIG®215XT Spool Gun Adapter K2703-1
Aluminum Feeding Kit K1703-1
Spindle Adapter for 8" O.D. Spindles K468
Dual Cylinder Mounting Kit K1702-1
Canvas Cover K2378-1
Welding Fume Extractors See publication MC05-183
Magnum®100SG Spool Gun K2532-1
Magnum®SG Spool Gun K487-25
Magnum®250 X Spool Gun K2490-1
TOTAL: