English dropdown-ico

Lincoln Electric 11521 manual

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97

Go to page of

Similar user manuals

A good user manual

The rules should oblige the seller to give the purchaser an operating instrucion of Lincoln Electric 11521, along with an item. The lack of an instruction or false information given to customer shall constitute grounds to apply for a complaint because of nonconformity of goods with the contract. In accordance with the law, a customer can receive an instruction in non-paper form; lately graphic and electronic forms of the manuals, as well as instructional videos have been majorly used. A necessary precondition for this is the unmistakable, legible character of an instruction.

What is an instruction?

The term originates from the Latin word „instructio”, which means organizing. Therefore, in an instruction of Lincoln Electric 11521 one could find a process description. An instruction's purpose is to teach, to ease the start-up and an item's use or performance of certain activities. An instruction is a compilation of information about an item/a service, it is a clue.

Unfortunately, only a few customers devote their time to read an instruction of Lincoln Electric 11521. A good user manual introduces us to a number of additional functionalities of the purchased item, and also helps us to avoid the formation of most of the defects.

What should a perfect user manual contain?

First and foremost, an user manual of Lincoln Electric 11521 should contain:
- informations concerning technical data of Lincoln Electric 11521
- name of the manufacturer and a year of construction of the Lincoln Electric 11521 item
- rules of operation, control and maintenance of the Lincoln Electric 11521 item
- safety signs and mark certificates which confirm compatibility with appropriate standards

Why don't we read the manuals?

Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Lincoln Electric 11521 alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Lincoln Electric 11521, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Lincoln Electric service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Lincoln Electric 11521.

Why one should read the manuals?

It is mostly in the manuals where we will find the details concerning construction and possibility of the Lincoln Electric 11521 item, and its use of respective accessory, as well as information concerning all the functions and facilities.

After a successful purchase of an item one should find a moment and get to know with every part of an instruction. Currently the manuals are carefully prearranged and translated, so they could be fully understood by its users. The manuals will serve as an informational aid.

Table of contents for the manual

  • Page 1

    SVM209-A April, 201 1 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAU[...]

  • Page 2

    Power MIG® 215XT SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ___________________[...]

  • Page 3

    SAFETY ii ii Power MIG® 215XT FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which r[...]

  • Page 4

    Power MIG® 215XT SAFETY iii iii FOR ELECTRICALL Y powered equipment. 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. 8.c. Ground the equipment in accordance w[...]

  • Page 5

    SAFETY iv iv Power MIG® 215XT PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique:[...]

  • Page 6

    SAFETY Power MIG® 215XT Electromagnetic Compatibility (EMC) Confor mance P roducts displaying the CE mark are in conformity with European Community Council Directive of 1 5 Dec 2004 on the appro ximation of the laws of the Member Stat es relating to electromagnetic compatibilit y , 2004/1 08/EC . It was manuf actured in conformit y with a national[...]

  • Page 7

    SAFETY Power MIG® 215XT Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surr ounding ar ea ma y ext end bey ond the boundar ies of the premises. Methods of Reducing Emissions Mains Supply W elding equipment should be c[...]

  • Page 8

    - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I Power MIG® 215XT Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 9

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 Power MIG® 215XT Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 10

    INST ALLA TION A-2 A-2 Power MIG® 215XT 75°C Copper Wire 75°C Copper Wire Input Ampere in Conduit in Conduit Input V oltage/ Fuse or Breaker Rating On A WG (IEC) Sizes A WG (IEC) Sizes Frequency (Hz) Size (Super Lag) Nameplate (For lengths (For lengths up to 100 ft.) exceeding 100 ft.) 208/50/60 60 45A 10 (6 mm 2 ) 8 (10 mm 2 ) 230/50/60 60 41A [...]

  • Page 11

    INST ALLA TION A-3 A-3 Power MIG® 215XT Read entire installation section before starting installation. SAFETY PRECAUTIONS INPUT POWER, GROUNDING AND CONNECTION DIAGRAMS 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 [...]

  • Page 12

    INST ALLA TION A-4 A-4 Power MIG® 215XT 3. The 208/230 volt 50/60 Hz model Power MIG® is shipped with a 7 ft.(2.1m). input cable and plug con- nected to the welder . 4. Using the instructions in Figure A.2, have a qualified electrician connect a receptacle (Customer Supplied) or cable to the input power lines and the system ground per the U.S. Na[...]

  • Page 13

    INST ALLA TION A-5 A-5 Power MIG® 215XT GUN AND CABLE INST ALLA TION The Magnum 250L gun and cable provided with the POWER MIG® 215XT 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. [...]

  • Page 14

    NOTES A-6 A-6 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 15

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 Power MIG® 215XT Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 16

    OPERA TION B-2 B-2 Power MIG® 215XT Read entire Operation section before operating the POWER MIG® 215XT . ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet cloth- ing. Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head ou[...]

  • Page 17

    OPERA TION B-3 B-3 Power MIG® 215XT PRODUCT DESCRIPTION The Power MIG® 215XT 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, consisti[...]

  • Page 18

    OPERA TION B-4 B-4 Power MIG® 215XT WIRE DRIVE ROLL The drive rolls installed with the POWER MIG® 215XT have two grooves one for .035(0.9mm) wire and the other for .045(1.2mm) wire. Drive roll size is indicated by the stenciling on the exposed side of the drive roll. WIRE SIZE CONVERSION P ARTS The POWER MIG® 215XT is rated to feed .025 through [...]

  • Page 19

    OPERA TION B-5 B-5 Power MIG® 215XT T O ST ART THE WELDER T urn the “Power Switch” switch to “ON”. With the desired voltage and wire speed selected, operate the gun trigger for welder output and to energize the wire feed motor . FEEDING WIRE ELECTRODE When triggering, the electrode and drive mechanism are electrically “hot” relative to[...]

  • Page 20

    OPERA TION B-6 B-6 Power MIG® 215XT 3. Press the trigger to feed the wire electrode through the gun and cable. For solid wire cut the electrode within approximately 3/8" (10 mm) of the end of the contact tip [3/4" (20 mm) for Outershield ® ]. 4. When welding with gas, turn on the gas supply and set the required flow rate (typically 25-3[...]

  • Page 21

    OPERA TION B-7 B-7 Power MIG® 215XT INPUT LINE VOL T AGE V ARIA TIONS High Line V oltage — 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. Low Line V oltage — Y ou may [...]

  • Page 22

    NOTES B-8 B-8 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 23

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 Power MIG® 215XT Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 24

    ACCESSORIES C-2 C-2 Power MIG® 215XT DRIVE ROLL KITS Refer to T able C.1 for various drive roll kits that are available for the POWER MIG® 215XT . The item in Bold is supplied standard with the POWER MIG® 215XT . T ABLE C.1 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1) This kit helps push feeding aluminum through standard machine feeder and[...]

  • Page 25

    ACCESSORIES C-3 C-3 Power MIG® 215XT MAGNUM 250LX PUSH-PULL GUN AND PUSH PULL ADAPTER For heavier duty aluminum applications when use of large 16 pound aluminum spools of wire are desired the follow- ing push pull gun and adapter kit are available. Magnum 250LX Push Pull Gun (K2704-1) This pistol grip push pull gun is similar to the Magnum 250LX s[...]

  • Page 26

    ACCESSORIES C-4 C-4 Power MIG® 215XT MAKING A WELD WITH THE SPOOL GUN ADAPTER KIT AND SPOOL GUN INST ALLED 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.[...]

  • Page 27

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 Power MIG® 215XT Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 28

    MAINTENANCE D-2 D-2 Power MIG® 215XT • Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser . • 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 [...]

  • Page 29

    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.) 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. FIGURE D.1 This screw should only be gently tightene[...]

  • Page 30

    MAINTENANCE D-4 D-4 Power MIG® 215XT GUN HANDLE DISASSEMBL Y The internal parts of the gun handle may be inspected or serviced if necessary . The gun handle consists of two halves that are held together with a collar on each end. T o open up the handle, turn the collars approximately 60 degrees counterclockwise (the same direction as removing a ri[...]

  • Page 31

    MAINTENANCE D-5 D-5 Power MIG® 215XT 1. Case Front Assembly 2. Rear Panel Assembly 3. Center Assembly 4. Wire Drive Assembly 5. Base & Power Component Assembly 6. Covers Assembly 6 6 2 2 3 3 4 4 5 5 1 1 FIGURE D.2 - MAJOR COMPONENT LOCA TIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Mast[...]

  • Page 32

    NOTES D-6 D-6 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 33

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 Power MIG® 215XT Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 34

    THEOR Y OF OPERA TION E-2 E-2 Power MIG® 215XT INPUT LINE VOL T AGE, MAIN TRANSFORMER, VOL T AGE SELECT OR SWITCH AND BAFFLE MOUNTED DIODE BRIDGE T h e s i n g l e p h a s e i n p u t p o w e r i s c o n n e c te d t o t h e Power MIG® 215XT through a line switch located on the front panel. A reconnect panel allows the user to configure the machi[...]

  • Page 35

    THEOR Y OF OPERA TION E-3 E-3 Power MIG® 215XT OUTPUT RECTIFICA TION, CONT ACTOR 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 weld[...]

  • Page 36

    THEOR Y OF OPERA TION E-4 E-4 Power MIG® 215XT CONTROL BOARD, GUN TRIGGER AND WIRE DRIVE MOT OR When the control board receives an activation command from the trigger circuit the control board supplies 12VDC which activates the gas solenoid and output contactor . It also supplies 2 to 29 VDC (depending on the wire speed setting) to the wire drive [...]

  • Page 37

    THEOR Y OF OPERA TION E-5 E-5 Power MIG® 215XT P R O T E C T I V E D E V I C E S A N D C I R C U I T S THERMAL AND OVERLOAD PROTECTION Th e Pow er MIG ® 215 XT has two bui lt- in pro tec tiv e th erm os tat s tha t res po nd to ex ce ssi ve te mpe ra tur es. On e is l oca ted on the mai n t ran sf orm er . Th e ot he r th erm os tat is lo cat ed [...]

  • Page 38

    NOTES E-6 E-6 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 39

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 Power MIG® 215XT T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use T roubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 40

    TROUBLESHOOTING AND REP AIR F-2 F-2 Power MIG® 215XT This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that t[...]

  • Page 41

    TROUBLESHOOTING AND REP AIR F-3 F-3 Power MIG® 215XT Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that [...]

  • Page 42

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 43

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 44

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 45

    FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubl[...]

  • Page 46

    WIRE FEEDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 tr[...]

  • Page 47

    WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 trouble[...]

  • Page 48

    WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 trouble[...]

  • Page 49

    Service and repair should be performed only 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 thr[...]

  • Page 50

    X8 X7 X6 X5 X4 X3 X2 FIGURE F .1 – OUTPUT SELECTOR SWITCH TERMINALS MAIN TRANSFORMER TEST (continued) TROUBLESHOOTING AND REP AIR F-12 F-12 Power MIG® 215XT W ARNING PROCEDURE THE ON/OFF POWER SWITCH will be “hot” during these tests. NOTE: Secondary voltages will vary proportionately with the primary input voltage. 1. Disconnect the main inp[...]

  • Page 51

    X1 FIGURE F .2 – LEAD X1 X9 X10 FIGURE F .3 – LEAD X9 & X10 MAIN TRANSFORMER TEST (continued) TROUBLESHOOTING AND REP AIR F-13 F-13 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 52

    T ABLE F .1 – TEST POINTS MAIN TRANSFORMER TEST (continued) 12. If ALL the voltages tested are incorrect or miss- ing, test for correct nameplate input voltage between the H1 lead at the ON/OFF POWER SWITCH to H2 or H3 at the reconnect panel. V oltage tested will vary depending on input voltage connection. See Wiring Diagram for test point loca[...]

  • Page 53

    Service and repair should be performed only 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 thr[...]

  • Page 54

    Black Tach J11 J11 Black Arm White Arm Blue Tach Red Tach FIGURE F .4 – PLUG J4 WIRE DRIVE MOTOR AND T ACHOMETER FEEDBACK TEST (continued) PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. T est for correct wire drive motor armature voltage. 1. Disconnect main input power to the machine. 2. Open the side panels and remove the tool tray u[...]

  • Page 55

    5. Make the following voltage tests: a. Turn the machine OFF between each test. b. Carefully insert the meter probes into the lead side of plug J4. See Figure F .4. c. Turn the machine ON and pull the gun trigger to conduct the voltage test. 6. If the voltage to the wire drive motor armature is zero, check the wires between plug J4 and the wire dri[...]

  • Page 56

    TEST FOR FEEDBACK VOL T AGE T O CONTROL BOARD 1. Disconnect the main AC input power to the machine. 2. Locate plug J4 and the tach leads. See Figure F .5. 3. Connect main input power to the machine. 4. Make the following voltage tests: a. Turn the machine OFF between each test. b. Carefully insert the meter probes into the lead side of plug J4. See[...]

  • Page 57

    Service and repair should be performed only 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 thr[...]

  • Page 58

    Front - + Negative Lead FIGURE F .6 – RECTIFIER TEST POINTS OUTPUT BRIDGE RECTIFIER TEST (continued) PROCEDURE 1. Remove input power to the Power MIG® 215XT machine. 2. Using the 3/8” nutdriver , remove the left case side. 3. Locate and disconnect the negative lead from the output rectifier bridge assembly . Be sure there is no electrical cont[...]

  • Page 59

    Service and repair should be performed only 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 thr[...]

  • Page 60

    107A 106C 106B Output Contactor FIGURE F .7 – CONT ACTOR TERMINALS AND LEADS CONT ACTOR TEST (continued) TROUBLESHOOTING AND REP AIR F-22 F-22 Power MIG® 215XT PROCEDURE 1. Remove the input power to the Power MIG® 215XT machine. 2. Using the 5/16” Nutdriver , remove the tool tray . 3. Locate and remove leads 106B, 106C and 107A from the conta[...]

  • Page 61

    This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division rep- resents 5 milliseconds in time. The machine was loaded with a resistance grid bank. No te : Scope probes connected at machine output terminals: (+) probe to electrode, [...]

  • Page 62

    This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division rep- resents 1.0 milliseconds in time. No te : Scope probes connected at machine output terminals: (+) probe to electrode, (-) probe to work. SCOPE SETTINGS V olts/Div .....[...]

  • Page 63

    This is NOT a typical DC output volt- age waveform. One output diode is not functioning. Note the increased ripple content. One diode was discon- nected to simulate an open or non- functioning output diode. Each vertical division represents 20 volts and each horizontal division represents 5 mil- liseconds in time. The machine was loaded with a resi[...]

  • Page 64

    This is NOT a typical DC output volt- age waveform. The output capacitors are not functioning. Note the lack of “filtering” in the output waveform. The output capacitor bank was disconnect- ed. Each vertical division represents 20 volts and each horizontal division represents 5 milliseconds in time. No te : Scope probes connected at machine out[...]

  • Page 65

    Service and repair should be performed only 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 thr[...]

  • Page 66

    DEPRESS L O C K I N G T A B O N MOUNTING PIN FIGURE F .8 – CONTROL BOARD MOUNTING PINS CONTROL BOARD REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Remove power to the machine. 2. Using a 5/16” nutdriver , remove the three screws securing the tool tray . 3. Locate the control board. 4. Disconnect all associated plugs and leads con-[...]

  • Page 67

    Service and repair should be performed only 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 thr[...]

  • Page 68

    Wire Drive FIGURE F .9 – WIRE DRIVE LOCA TION WIRE DRIVE MOTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Remove power to the machine. 2. Lift cover to gain access to the wire drive. See Figure F .9. 3. Using a pair of pliers, disconnect the gas hose from the bottom of the wire drive. See Figure F .10. 4. Using a 9/16” nut driv[...]

  • Page 69

    Gas Hose 9/16" Bolt 5/16" Sheet Metal Screws FIGURE F .10 – WIRE DRIVE HOSE & LEAD LOCA TION 5/16" Monuting Screws FIGURE F .1 1 – MOUNTING SCREW LOCA TIONS WIRE DRIVE MOTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-31 F-31 Power MIG® 215XT Return to Section TOC Return to Section TOC Return[...]

  • Page 70

    WIRE DRIVE MOTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) 1. Place the new wire drive assembly into its prop- er position. 2. Connect plug J4. 3. Maneuver assembly back into its original posi- tion. 4. Replace all mounting screws previously removed. 5. Using a 3/4” nut driver , replace the thick black lead previously removed. 6. Reconnect t[...]

  • Page 71

    Service and repair should be performed only 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 thr[...]

  • Page 72

    OUTPUT DIODE BRIDGE RECTIFIER FIGURE F .12 – OUTPUT DIODE BRIDGE RECTIFIER LOCA TION OUTPUT DIODE BRIDGE RECTIFIER REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Using a 3/8” nutdriver , remove the left side of the case wraparound cover . 2. Locate the output diode bridge rectifier . See Figure F .12. 3. Using a 1/2” nutdriver la[...]

  • Page 73

    5/16" Mounting Bracket Mounting Bolts 1/2" Rectifier Mounting Bolts Mounting Bracket FIGURE F .13 – OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET OUTPUT DIODE BRIDGE RECTIFIER REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-35 F-35 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Sect[...]

  • Page 74

    NOTES F-36 F-36 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 75

    Service and repair should be performed only 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 thr[...]

  • Page 76

    LOWER RIGHT CASE WRAP AROUND COVER CAP ACIT OR BANK ASSEMBL Y FIGURE F .14 – CAP ACITOR BANK LOCA TION OUTPUT CAP ACITORS REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Using a 3/8” nutdriver , remove the lower right side case wraparound cover . See Figure F .14. 2. Locate capacitor bank. See Figure F .14. 3. Label and remove the f[...]

  • Page 77

    } { 3/8" Nuts & Lock washers (3 places) Lead Mounting Bolts FIGURE F .15 – MOUNTING SCREW / BOL T LOCA TIONS OUTPUT CAP ACITORS REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-39 F-39 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC[...]

  • Page 78

    NOTES F-40 F-40 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 79

    Service and repair should be performed only 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 thr[...]

  • Page 80

    Main T ransformer 1/2" Mounting Bolts FIGURE F .16 – MAIN TRANSFORMER LOCA TION MAIN TRANSFORMER REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Using a 3/8” nutdriver , remove both sides of the case wraparound cover . 2. Using a 5/16” nutdriver , remove the tool tray . 3. Locate the main transformer . See Figure F .16. 4. La[...]

  • Page 81

    X10 X9 104B 104C H1B FIGURE F .17 – LEADS X9, X10, 104B, 104C, & H1B MAIN TRANSFORMER REMOV AL AND REPLACEMENT PROCEDURE (continued) 15. Carefully maneuver the main transformer out the left side of the machine. NOTE: T wo people may be needed to maneuver the main transformer out of the machine. REPLACEMENT 1. Carefully maneuver the new main t[...]

  • Page 82

    X8 X7 X6 X5 X4 X3 X2 FIGURE F .18 – LEADS SWITCH LEADS Front - + 121 1 18 FIGURE F .19 – LEAD 121 & 1 18 MAIN TRANSFORMER REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-44 F-44 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return t[...]

  • Page 83

    5/16" Nut REAR ACCESS P ANEL FIGURE F .20 – REAR ACCESS P ANEL 230V 208V 4 L1 L2 Lead 1 18 FIGURE F .21 – REAR ACCESS P ANEL (CLOSE-UP) MAIN TRANSFORMER REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-45 F-45 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section T[...]

  • Page 84

    NOTES F-46 F-46 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 85

    Service and repair should be performed only 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 thr[...]

  • Page 86

    REAR 5/16" Bolts } } Fan Mounting Band 1 1/32" Mounting Nuts Fan Blade Fan Motor FIGURE F .22 – F AN MOUNTING BOL TS F AN BLADE / MOT OR REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Using a 3/8” nutdriver , remove the lower right side of the case wraparound cover . 2. Perform the Output Capacitors Removal and Replacemen[...]

  • Page 87

    Service and repair should be performed only 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 thr[...]

  • Page 88

    107A 106C 106B Output Contactor FIGURE F .23 – OUTPUT CONT ACTOR LEADS OUTPUT CONT ACTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Using a 5/16” nutdriver , remove the three screws securing the tool tray . 2. Locate the output contactor . See Figure F .23. 3. Using a 7/16” wrench, label and remove the two thick black leads a[...]

  • Page 89

    7/16" Mounting Bolts FIGURE F .24 – OUTPUT CONT ACTOR MOUNTING BOL TS OUTPUT CONT ACTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-51 F-51 Power MIG® 215XT Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC R[...]

  • Page 90

    TROUBLESHOOTING AND REP AIR F-52 F-52 Power MIG® 215XT RETEST AFTER REP AIR INPUT IDLE AMPS AND W A TTS OPEN CIRCUIT VOL T AGE WIRE SPEED RANGE Input V olts/Herts 230/60 Maximum Idle Amps 2.0 Maximum Idle Watts 150 35 - 40 VDC 50 - 700 IPM (1.27 - 17.8 m/minute) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TO[...]

  • Page 91

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 Power MIG® 215XT Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram (L12184-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 92

    ElEcTrical DiaGramS G-2 pOWEr miG® 215XT WiriNG DiaGram - cOmplETE machiNE - l12184-1 POW ER MIG 2 15X T (208/ 220/ 230 V) FOR COD E 1 1521 J1 C AVIT YN U M BE RING SE QUENCE (COMPONENT S IDE OF P .C. B OARD) J2 NOTES: N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. N.B. THIS DIA[...]

  • Page 93

    ElEcTrical DiaGramS G-3 pOWEr miG® 215XT SchEma Tic - cOmplETE machiNE - l12308-1 pG1 J1 , J1 4 CAVITY NUM BERI NG SEQ UE N CE ( COMPONENT S IDE OF P.C. BOARD ) J2 J3 9 PA J4 ( T RI GG ER , T ACH OMET ER , MOT OR S IDE) 8 16 1 4 6 1 3 8 1 4 5 1 2 4 6 1 3 ( NO N -LEAD SIDE OF CO N NECTOR ) LE A D COLO R CO DE: B-BL ACK G-GRE EN O-ORA NG E R-RE D [...]

  • Page 94

    ElEcTrical DiaGramS G-4 pOWEr miG® 215XT SchEma Tic - cOmplETE machiNE - l12308-1 pG2 J1 , J1 4 CAVITY NUM BERI NG SEQ UE N CE ( COMPONENT S IDE OF P.C. BOARD ) J2 J3 9 PA J4 ( T RI GG ER , T ACH OMET ER , MOT OR S IDE) 8 16 1 4 6 1 3 8 1 4 5 1 2 4 6 1 3 ( NO N -LEAD SIDE OF CO N NECTOR ) LE A D COLO R CO DE: B-BL ACK G-GRE EN O-ORA NG E R-RE D [...]

  • Page 95

    ElEcTrical DiaGramS G-5 pOWEr miG® 215XT SchEma Tic - cONTrOl bD - G4414 pG1 G-5 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return t[...]

  • Page 96

    ElEcTrical DiaGramS G-6 pOWEr miG® 215XT SchEma Tic - cONTrOl bD - G4414 pG2 G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return t[...]

  • Page 97

    ElEcTrical DiaGramS G-7 pOWEr miG® 215XT SchEma Tic - cONTrOl bD - G4414 pG3 G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return t[...]