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Lincoln Electric POWER MIG 11521 Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
SVM209-A
April, 2011
®
POWER MIG
215XT
11521
For use with machine code number:
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 © 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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Summary of Contents for Lincoln Electric POWER MIG 11521

  • Page 1: Service Manual

    RETURN TO MAIN MENU SVM209-A April, 2011 ® POWER MIG 215XT 11521 For use with machine code number: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety increased by proper installation .

  • Page 2: California Proposition 65 Warnings

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area.If this is not possible, cover them to prevent 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.
  • Page 5 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: a.
  • Page 6 SAFETY Electromagnetic Compatibility (EMC) Conformance Introduction Installation and Use Assessment of Area Power MIG® 215XT...
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) Methods of Reducing Emissions Mains Supply Maintenance of the Welding Equipment Welding Cables Equipotential Bonding Earthing of the Workpiece Screening and Shielding Power MIG® 215XT...
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety ................i-vi Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 10 TECHNICAL SPECIFICATIONS – POWER MIG Standard Voltage/Phase/Frequency 208/230/1/50/60 Hz Duty Cycle Welding Current Range 30 – 250Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage/ Fuse or Breaker Frequency (Hz) Size (Super Lag) 208/50/60 230/50/60 Wire Speed Height 31.79 in 808 mm OPERATING TEMPERATURE RANGE -4°F to 104°F(-20°C to +40°C)

  • Page 11: Installation

    Roll the machine off the skid assembly. LOCATION 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...

  • Page 12: Output Polarity Connections

    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. FIGURE A.2 — Receptacle Diagram CONNECT TO A SYSTEM GROUNDING WIRE.

  • Page 13: Gun And Cable Installation

    Be sure that the contact tip, liner, and drive rolls all match the size of the wire being used. WARNING Turn the welder power switch off before installing gun and cable. 1. Lay the cable out straight.
  • Page 14 NOTES Power MIG® 215XT...
  • Page 15 To Start the Welder ........

  • Page 16: Operation

    Read entire Operation section before operating the POWER MIG® 215XT. Observe all safety information throughout this manual. ------------------------------------------------------------ OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet cloth- ing. Insulate yourself from work and ground.

  • Page 17: Product Description

    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, consisting of continuous full range wire feed speed control, and 7 output voltage tap selections provides versatility with ease of use and...

  • Page 18: Wire Drive Roll

    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 PARTS The POWER MIG®...

  • Page 19: To Start The Welder

    TO START THE WELDER Turn 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 WARNING When triggering, the electrode and drive mechanism are electrically “hot”...

  • Page 20: Making A Weld

    5. Loosen the socket head cap screw that holds the connector bar against the gun bushing. Important: Do attempt remove the socket head cap screw. 6. Remove the outer wire guide, and push the gun bushing out of the wire drive. Because of the pre- cision fit, light tapping may be required to remove the gun bushing.

  • Page 21: Avoiding Wire Feeding Problems

    The POWER MIG® 215XT 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.
  • Page 22 NOTES Power MIG® 215XT...
  • Page 23 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Drive Roll Kits .

  • Page 24: Drive Roll Kits

    DRIVE ROLL KITS Refer to Table 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. TABLE C.1 Wire Size .023”-.030” (0.6-0.8 mm) .035” (0.9 mm) Solid .045”...
  • Page 25 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 spool gun except it is designed to feed large spools of wire.
  • Page 26 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.
  • Page 27 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 28: Gun Cable Cleaning

    GENERAL MAINTENANCE 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.
  • Page 29 LINER REMOVAL AND REPLACE- MENT 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 Replacement Size Stencilled Gas Diffuser Gas Diffuser Diameter of Liner Part on End of Electrodes Used...

  • Page 30: Gun Handle Disassembly

    GUN HANDLE DISASSEMBLY 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. 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.
  • Page 31 MAINTENANCE FIGURE D.2 - MAJOR COMPONENT LOCATIONS 1. Case Front Assembly 2. Rear Panel Assembly 3. Center Assembly 4. Wire Drive Assembly 5. Base & Power Component Assembly 6. Covers Assembly Power MIG® 215XT...
  • Page 32 NOTES Power MIG® 215XT...
  • Page 33 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 Input Power Circuit .

  • Page 34: Theory Of Operation

    THEORY OF OPERATION CIRCUIT 115V BREAKER RECEPTACLE MOTOR LINE SWITCH RECONNECT MAIN PANEL TRANSFORMER INPUT LINE VOLTAGE, MAIN TRANSFORMER, VOLTAGE SELECTOR SWITCH AND BAFFLE MOUNTED DIODE BRIDGE The single phase input power is connected to the Power MIG® 215XT through a line switch located on the front panel.
  • Page 35 THEORY OF OPERATION CIRCUIT 115V BREAKER RECEPTACLE MOTOR LINE SWITCH RECONNECT MAIN PANEL TRANSFORMER 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.
  • Page 36 THEORY OF OPERATION CIRCUIT 115V BREAKER RECEPTACLE MOTOR LINE SWITCH RECONNECT MAIN PANEL TRANSFORMER CONTROL BOARD, GUN TRIGGER AND WIRE DRIVE MOTOR 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.
  • Page 37 One is located on the main transformer. 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.
  • Page 38 NOTES Power MIG® 215XT...
  • Page 39 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 40: How To Use Troubleshooting Guide

    TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 41: Troubleshooting And Repair

    - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - 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 prop- er failure analysis.
  • Page 42 The cooling fan is running. 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 43 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 1-888-935-3877.
  • Page 44 The wire feed functions nor- mally. 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 45 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 46 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 47 The arc is unstable and or “hunting” 1. Check for a worn or melted con- 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 1-888-935-3877.
  • Page 48 The contact tip seizes in the gas dif- fuser. 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 1-888-935-3877. POSSIBLE AREAS OF...

  • Page 49: Main Transformer Test

    F-11 MAIN TRANSFORMER TEST 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 throughout this manual.
  • Page 50 TROUBLESHOOTING AND REPAIR F-12 MAIN TRANSFORMER TEST (continued) FIGURE F.1 – OUTPUT SELECTOR SWITCH TERMINALS PROCEDURE WARNING THE ON/OFF POWER SWITCH will be “hot” during these tests. NOTE: Secondary voltages proportionately with the primary input voltage. 1. Disconnect the main input power supply to the machine.
  • Page 51 TROUBLESHOOTING AND REPAIR F-13 F-13 MAIN TRANSFORMER TEST (continued) FIGURE F.2 – LEAD X1 FIGURE F.3 – LEAD X9 & X10 Power MIG® 215XT...
  • Page 52 TROUBLESHOOTING AND REPAIR F-14 MAIN TRANSFORMER TEST (continued) INPUT VOLTAGE 230 VAC 230 VAC 230 VAC 230 VAC 230 VAC 230 VAC 230 VAC 230 VAC 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.

  • Page 53: Wire Drive Motor And Tachometer Feedback Test

    F-15 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST 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 throughout this manual.
  • Page 54 TROUBLESHOOTING AND REPAIR F-16 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) Black Tach PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. Test 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 using a 5/16”...
  • Page 55 TROUBLESHOOTING AND REPAIR F-17 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) 5. Make the following voltage tests: WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • All input power must be electrically disconnected before proceeding.
  • Page 56 TROUBLESHOOTING AND REPAIR F-18 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) Black Tach TEST FOR FEEDBACK VOLTAGE TO CONTROL BOARD 1. Disconnect the main AC input power to the machine. 2. Locate plug J4 and the tach leads. Figure F.5. 3.

  • Page 57: Output Bridge Rectifier Test

    F-19 OUTPUT BRIDGE RECTIFIER TEST 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 throughout this manual.
  • Page 58 TROUBLESHOOTING AND REPAIR F-20 OUTPUT BRIDGE RECTIFIER TEST (continued) FIGURE F.6 – RECTIFIER TEST POINTS 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.

  • Page 59: Contactor Test

    TROUBLESHOOTING AND REPAIR F-21 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 throughout this manual.
  • Page 60 TROUBLESHOOTING AND REPAIR F-22 CONTACTOR TEST (continued) FIGURE F.7 – CONTACTOR TERMINALS AND LEADS 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 contactor coil terminals.
  • Page 61 TROUBLESHOOTING AND REPAIR F-23 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED 10.0V MACHINE LOADED TO 200 AMPS AT 22 VDC (MAX TAP “G”) 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.
  • Page 62 TROUBLESHOOTING AND REPAIR F-24 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”) 20.0V 1.0 ms 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.
  • Page 63 TROUBLESHOOTING AND REPAIR F-25 ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED ONE OUTPUT DIODE NOT FUNCTIONING 20.0 V MACHINE LOADED TO 180 AMPS AT 16 VDC (MAX TAP “G”) This is NOT a typical DC output volt- age waveform. One output diode is not functioning.
  • Page 64 TROUBLESHOOTING AND REPAIR F-26 ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”) 20.0 V 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.
  • Page 65 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING 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 throughout this manual.
  • Page 66 TROUBLESHOOTING AND REPAIR F-28 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.8 – CONTROL BOARD MOUNTING PINS DEPRESS LOCKING TAB ON MOUNTING PIN PROCEDURE 1. Remove power to the machine. 2. Using a 5/16” nutdriver, remove the three screws securing the tool tray. 3.
  • Page 67 F-29 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.
  • Page 68 TROUBLESHOOTING AND REPAIR F-30 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE 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.
  • Page 69 TROUBLESHOOTING AND REPAIR F-31 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.10 – WIRE DRIVE HOSE & LEAD LOCATION FIGURE F.11 – MOUNTING SCREW LOCATIONS 5/16" Monuting Screws (continued) 5/16" Sheet Metal Screws 9/16" Bolt Gas Hose Power MIG® 215XT F-31...
  • Page 70 TROUBLESHOOTING AND REPAIR F-32 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE 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.
  • Page 71 OUTPUT DIODE BRIDGE RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.
  • Page 72 TROUBLESHOOTING AND REPAIR F-34 OUTPUT DIODE BRIDGE RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.12 – OUTPUT DIODE BRIDGE RECTIFIER LOCATION OUTPUT DIODE BRIDGE RECTIFIER PROCEDURE 1. Using a 3/8” nutdriver, remove the left side of the case wraparound cover. 2.
  • Page 73 TROUBLESHOOTING AND REPAIR F-35 OUTPUT DIODE BRIDGE RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.13 – OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET 1/2" Rectifier Mounting Bolts 5/16" Mounting Bracket Mounting Bolts Power MIG® 215XT F-35 Mounting Bracket...
  • Page 74 NOTES F-36 F-36 Power MIG® 215XT...
  • Page 75 F-37 OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.
  • Page 76 TROUBLESHOOTING AND REPAIR F-38 OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.14 – CAPACITOR BANK LOCATION 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.
  • Page 77 TROUBLESHOOTING AND REPAIR F-39 F-39 OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.15 – MOUNTING SCREW / BOLT LOCATIONS Lead Mounting Bolts 3/8" Nuts & Lock washers (3 places) Power MIG® 215XT...
  • Page 78 NOTES F-40 F-40 Power MIG® 215XT...
  • Page 79 F-41 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.

  • Page 80: Main Transformer

    TROUBLESHOOTING AND REPAIR F-42 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.16 – MAIN TRANSFORMER LOCATION Main Transformer 1/2" Mounting Bolts 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.
  • Page 81 TROUBLESHOOTING AND REPAIR F-43 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.17 – LEADS X9, X10, 104B, 104C, & H1B 15. Carefully maneuver the main transformer out the left side of the machine. NOTE: Two people may be needed to maneuver the main transformer out of the machine.
  • Page 82 TROUBLESHOOTING AND REPAIR F-44 F-44 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.18 – LEADS SWITCH LEADS FIGURE F.19 – LEAD 121 & 118 Power MIG® 215XT...
  • Page 83 TROUBLESHOOTING AND REPAIR F-45 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.21 – REAR ACCESS PANEL (CLOSE-UP) 230V (continued) FIGURE F.20 – REAR ACCESS PANEL REAR ACCESS PANEL Lead 118 208V Power MIG® 215XT F-45 5/16" Nut...
  • Page 84 NOTES F-46 F-46 Power MIG® 215XT...
  • Page 85 F-47 FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.
  • Page 86 TROUBLESHOOTING AND REPAIR F-48 FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.22 – FAN MOUNTING BOLTS REAR 5/16" Bolts PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side of the case wraparound cover. 2. Perform the Output Capacitors Removal and Replacement Procedure.
  • Page 87 F-49 OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.
  • Page 88 TROUBLESHOOTING AND REPAIR F-50 OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.23 – OUTPUT CONTACTOR LEADS 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 at the top of the output con- tactor.
  • Page 89 TROUBLESHOOTING AND REPAIR F-51 F-51 OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.24 – OUTPUT CONTACTOR MOUNTING BOLTS 7/16" Mounting Bolts Power MIG® 215XT...

  • Page 90: Retest After Repair

    TROUBLESHOOTING AND REPAIR F-52 F-52 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts/Herts Maximum Idle Amps Maximum Idle Watts 230/60 OPEN CIRCUIT VOLTAGE 35 - 40 VDC WIRE SPEED RANGE 50 - 700 IPM (1.27 - 17.8 m/minute) Power MIG®...
  • Page 91 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (L12184-1) .

  • Page 92: Electrical Diagrams

    WiriNG DiaGram - cOmplETE machiNE - l12184-1 CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) TO SINGLE PHASE SUPPLY LINE 208V RECONNECT PANEL TO GROUND PER NATIONAL ELECTRICAL CODE 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. ElEcTrical DiaGramS POWER MIG 215XT (208/220/230V) GENERAL INFORMATION...
  • Page 93 SchEmaTic - cOmplETE machiNE - l12308-1 pG1 L12308-1 ENGINEERING CONTROLLED MANUFACTURER: LOCATEDON CASEBACK TO SINGLE PHASE SUPPLY LINE TO GROUND PER NATIONAL ELECTRICAL CODE ElEcTrical DiaGramS CHANGE DETAIL: REVISED PAGE 2. 40 VDC 1106A X9 1114A RECTIFIER DIODE BRIDGE MOVED TO CONTROL BOARD ON CODE 11099 AND HIGHER LOCATEDON...
  • Page 94 SchEmaTic - cOmplETE machiNE - l12308-1 pG2 L12308-1 ENGINEERING CONTROLLED MANUFACTURER: MOTOR+SPEEDCONTROL FROMCONTROLBOARD TOSTANDARDFEEDMOTOR 16J1 - POW ERTOSTANDARDGASSOLENOIDANDUSED FORSPOOL GUNDETECT(ATCONTROL BOARD) FROMSTANDARDGUNTRIGGER +40FROMDIODEDRIDGE 4J1 - TOCONTROL BOARD(TRIGGER) ElEcTrical DiaGramS REVISED PAGE 2. CHANGE DETAIL: CONTROLSTHE FUNCTIONALITYOF THESSTANDARDFEEDMOTORCIRCUIT THEMACHINE ALSOISUSEDFORALLTHESPOOL GUN MOTORSW HENSELECTEDW ITH ADAPTERPANEL.
  • Page 95 SchEmaTic - cONTrOl bD - G4414 pG1 TOGGLE TRIGGER INPUTS SWITCH IN SPOOL GUN KIT SPOOL TRIGGER TRIGGER +15V MOTOR_SELECT 6 J14 0.2A 2.21K 0.1W +15V 15 J14 TRIGGR_INTRLK_EN 3 D24 3 J14 R106 0.2A 2.21K 0.1W 4 J14 GAS ON/OFF 0.2A 2.21K 0.1W...
  • Page 96 SchEmaTic - cONTrOl bD - G4414 pG2 PRIMARY_POSITIVE 25-75VDC OPERATION OR 20-60VAC OPERATION (D25 REQ.) COMMON ElEcTrical DiaGramS +DC_IN 43.2K 0.0033uF 0.0033F 0.0018F 630V 0.01uF 100V 100V 200V CLUSTER 3 CLUSTER 2 33.2 39.2K 0.1W 0.5W 0.1W 2.21K VREF RT/CT 400V COMP 2842AD8...
  • Page 97 SchEmaTic - cONTrOl bD - G4414 pG3 ElEcTrical DiaGramS VSENSE ISENSE P0[0] P0[1] INPUT_VOLTAGE P0[2] SPOOL_SPOT P0[3] SPEED_CTRL P0[4] BURNBACK P0[5] P0[6] SC_ISENSE P0[7] PEAK_CUR_LIM P1[0] P1[1] DATA THERMOSTAT INDICATOR LIGHT P1[2] CALIBRATE SCLK P1[3] CY8C27443SX XRES TRIGGER MOTOR_SELECT XRES CLUSTER 1 NOTE: This diagram is for reference only.

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Power mig 215xt

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