Lincoln Electric SPEEDTEC 215C Service Manual
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Lincoln Electric SPEEDTEC 215C Service Manual

Lincoln Electric SPEEDTEC 215C Service Manual

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SVM 3057
Rev.00 03-2016
SPEEDTEC
215C
®
For use with machines having code numbers: 50314
LINCOLN ELECTRIC EUROPE
www.lincolnelectric.eu

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  • Page 1 SVM 3057 Rev.00 03-2016 SPEEDTEC 215C ® For use with machines having code numbers: 50314 LINCOLN ELECTRIC EUROPE www.lincolnelectric.eu...

  • Page 2: Table Of Contents

    INDEX OF CONTENTS TECHNICAL SPECIFICATIONS ............................. 2 INSTALLATION AND OPERATOR INSTRUCTIONS..................... 5 MAINTENANCE ................................16 THERMAL PROTECTION ............................. 17 MAJOR COMPONENTS LOCATION ........................... 17 THEORY OF OPERATION ............................17 GENERAL DESCRIPTION ............................20 HOW TO USE TROUBLESHOOTING GUIDE ......................24 CASE COVER REMOVAL AND DC LINK CAPACITOR DISCHARGE PROCEDURE ..........

  • Page 3: Technical Specifications

    TECHNICAL SPECIFICATIONS NAME INDEX SPEEDTEC 215C K14146-1 INPUT Input Voltage U 230 Vac ± 10%, 1-phase 115 Vac ± 10%, 1-phase Frequency 50/60 Hz Input Amperes I 1max Input Power at Rated Cycle (40°C) 6,2kVA @ 25% Duty Cycle 2,6kVA @ 40% Duty Cycle cos φ...
  • Page 4 Accessories K10413-15-3M The gas-cooled gun LG150 to GMAW process - 3m. KP10461-1 Gas nozzle conical Ø12mm. KP10440-06 Contact Tip M6x25mm ECu 0.6mm KP10440-08 Contact Tip M6x25mm ECu 0.8mm KP10440-09 Contact Tip M6x25mm ECu 0.9mm KP10440-10 Contact Tip M6x25mm ECu 1.0mm KP10440-10A Contact Tip M6x25mm Al 1.0mm KP10468...
  • Page 5 Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages caused by improper installation, improper care or abnormal operation.

  • Page 6: Installation And Operator Instructions

    The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time the operator’s manual. Introduction For GMAW and FCAW-SS process, the technical General Description specification describes: The welding machines SPEEDTEC 215C enables  Type of welding wire welding:  Wire diameter ...
  • Page 7 Advanced menu:  connection of ground wires from the machine to the input Recalls advanced menu (default)  source. The welding machine SPEEDTEC 215C must be Recalls user memory. connected to a correctly installed plug-in socket with an  Inductance.
  • Page 8  Take off the terminal block’s shield [17]. a standard equipment. Connect the power lead with  plug to the main supply before turning power on. The tip of the wire on the terminal block [16] and work lead fix as is shown in the Table 1 or the 20.

  • Page 9: Loading The Electrode Wire

    Table 1 WORK LEAD Table 2 WORK LEAD that the spool turns anticlockwise when the wire [15] is fed into the wire feeder. Loading the Electrode Wire  Make sure that the spool locating pin goes into the  Turn the machine off. fitting hole on the spool.
  • Page 10 Turn the input power off of the welding power source before installation or changing drive rolls. Figure 5 SPEEDTEC 215C is equipped with drive roll V0.8/V1.0 26. Fastening cap. for steel wire. For others wire sizes, is available the 27. Adjusting Allen screw M8.
  • Page 11 Welding GMAW, FCAW-SS Welding GMAW, FCAW-SS Process Process in Manual Mode SPEEDTEC 215C can be used to welding GMAW and In manual mode can be set: FCAW-SS process. It has been provided with synergic GMAW process. Basic menu Advanced menu SPEEDTEC 215C packaging does not include the gun ...

  • Page 12: Welding Smaw (Mma) Process

    Welding SMAW (MMA) Process Welding GMAW in Synergic Mode SPEEDTEC 215C does not include the electrode holder In synergic mode, the welding load voltage is not set by with lead necessary for SMAW welding, but the one can user. The correct welding load voltage will set by the be purchased separately.

  • Page 13: Error's Message

    Error’s Message Welding GTAW Process SPEEDTEC 215C can be used to GTAW process with DC (-). Arc ignition can be achieved only by lift TIG method (contact ignition and lift ignition). SPEEDTEC 215C does not include the torch to GTAW welding, but the one can be purchased separately.
  • Page 14 Guide’s Marking Interface SPEEDTEC 215C Description of the user interface in "Quick Guide" chapter Select Welding Process SMAW (MMA) Welding Basic menu GMAW (MIG/MAG) Burn-back Brightness Level Manual Welding View Software and FCAW- Self shielded Run-in WFS Hardware Version Manual Welding...

  • Page 15: Electromagnetic Compatibility (Emc)

    Lincoln Electric. Before installing the machine, the operator must check the work area for any devices that may malfunction because of electromagnetic disturbances.

  • Page 16: Maintenance

    For any repair operations, modifications or maintenances, it is recommended to contact the nearest Technical Service Center or Lincoln Electric. Repairs and modifications performed by unauthorized service or personnel will cause, that the manufacturer’s warranty will become null and void.

  • Page 17: Input Filter Capacitor Discharge Procedure

    MAINTENANCE WARNING (two) minutes. Access to the terminals DC+ and DC – of the Main Board to check if capacitors are discharged is not possible without removing the board from the machine. For this reason ALL operations to remove the Main Board have to be done in a ELECTRIC SHOCK can kill safety way using electrically insulate gloves and insulate tools (pliers, screwdrivers, etc..)

  • Page 18: Thermal Protection

    If the fan is not turning or the air intake louvers were obstructed , then the power must be switched off and the fan problem or air obstruction must be corrected. MAJOR COMPONENTS LOCATION SPEEDTEC 215C EMI Filter Main Board...

  • Page 19: Theory Of Operation

    THEORY OF OPERATION  General description  Main Board  Output choke – Polarity change – User Interface  Protection Circuits  IGBT operation BLOCK DIAGRAM...

  • Page 20: General Description

    GENERAL DESCRIPTION single phase input power 115Vac or 230Vac. It is GENERAL DESCRIPTION environmentally hardened to an IP23 rating for ® The SPEEDTEC 215C are industrial arc welding operating in difficult environments. power sources which utilizes single phase input power, to produce constant voltage or constant EMI FILTER current output.

  • Page 21: Main Board

    MAIN BOARD (PFC CIRCUIT - INVERTER CIRCUIT – OUTPUT CIRCUIT – WIRE DRIVE MOTOR) to K2 relay to close and the soft-start process MAIN BOARD (PFC CIRCUIT, INVERTER starts using a 25 ohms PTC to pre-charge the CIRCUIT, OUTPUT CIRCUIT, WIRE DRIVE BUS capacitors.
  • Page 22 MAIN BOARD (PFC CIRCUIT - INVERTER CIRCUIT – OUTPUT CIRCUIT – WIRE DRIVE CIRCUIT) (continued) MAIN BOARD (PFC CIRCUIT, INVERTER CIRCUIT, OUTPUT CIRCUIT, WIRE DRIVE CIRCUIT) The output transformer, located on the main board, insulates the primary circuit from the secondary circuit.
  • Page 23 OUTPUT CHOKE – POLARITY CHANGE – USER INTERFACE OUTPUT CHOKE, POLARITY CHANGE, USER INTERFACE The DC output is applied through an output choke coil. The choke provides current filtering for the welding output. Polarity Change terminal block enables to set the welding polarity (+ ;...

  • Page 24: Overload Protection

    the duty cycle and output rating. If excessive OVERLOAD PROTECTION operating temperature should occur, the Thermal LED indicator on the control board, will turn ON ® SPEEDTEC 215C are electrically protected from and the thermostat will prevent output current. producing higher than normal output currents. An electronic protection circuit limits the current to The thermal protection devices are self-resetting within the capabilities of the machine.
  • Page 25 TROUBLESHOOTING AND REPAIR SECTION  How to use troubleshooting Guide  Troubleshooting Guide  Case cover removal and capacitor discharge procedure...

  • Page 26: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only 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 27 WARNING 4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board. NOTE: Allow the machine to heat up so that all ELECTRIC SHOCK can kill electrical components can reach their operating temperature. ...

  • Page 28: Troubleshooting

    TROUBLESHOOTING !! WARNING !! BEFORE CONNECT POWER SUPPLY, MAKE A CAREFUL VISUAL INSPECTION INSIDE THE MACHINE , CHECK ALL THE BOARDS AND HARNESSES. POSSIBLE AREAS OF RECOMMENDED COURSE PROBLEMS / SYMPTOMS CHECKS MISADJUSTMENT(S) OF ACTION  INPUT POWER BRIDGE IS IN SHORT CIRCUIT THE LINE CIRCUIT BREAKER ...

  • Page 29: Case Cover Removal And Dc Link Capacitor Discharge Procedure

    DISCHARGE 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 30: Necessary Tool

    ® 215C – SIDE CASE COVER REMOVAL SPEEDTEC Figure 1 Necessary tool: 8 mm Nut driver Procedure: 1. Turn on/off switch to off position. 2. Disconnect Input Power from the machine ! 3. Remove the 5 screws (A) from the right panel. See Figure1 4.

  • Page 31: Discharge Procedure

    DISCHARGE PROCEDURE (two) minutes. Access to the terminals DC+ and DC – of the Main WARNING Board to check if capacitors are discharged is not possible without removing the board from the machine. For this reason ALL operations to remove the Main Board have to be done in a safety way using electrically insulate gloves ELECTRIC SHOCK can kill and insulate tools (pliers, screwdrivers, etc..)

  • Page 32: Emi Filter Board Resistance Test

    EMI FILTER BOARD RESISTANCE TEST WARNING Service and repair should be performed by only 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 33: Test Procedure

    EMI FILTER BOARD RESISTANCE TEST (continued) Input cable Neutral – N L’ & N’ To Main Board Input cable Phase - L TEST PROCEDURE ® 1. Remove main input power to the SPEEDTEC 215C 2. WARNING ! EMI filter is directly connected to the main line, be sure to have the plug removed from the mains ! 3.

  • Page 34: Main Board Resistance Test

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
  • Page 35 MAIN BOARD RESISTANCE TEST (continued) Diode DC + DC - Diode V9 pinout INPUT RECT. BRIDGE TEST PROCEDURE ® 1. Remove main input power to the SPEEDTEC 215C 2. Perform the Discharge procedure 3. Follow the Main board disassembly operations available in this Service Manual. 4.
  • Page 36 MAIN BOARD RESISTANCE TEST (continued) V8 – V6 IGBT pinout V20 – V18 V17 – V15 TEST PROCEDURE 7. Check PFC IGBT V18 and V20, using the Volt-Ohmmeter (diode test mode), following the Table tests 2 8. Check Inverter IGBT V6-V8 and V15-V17, using the Volt-Ohmmeter (diode test mode), following the Table tests 2 IGBT V6-V8-V15-V16-V18-V20 - Table tests 2 Positive Probe (RED)
  • Page 37 MAIN BOARD RESISTANCE TEST (continued) Output Diode pinout Anodes Cathodes Anodes Cathodes TEST PROCEDURE 9. Check the output diodes V2,V3,V4,V11,V12,V13 with multi meter in diode test mode, for short, following the Table tests 3 10. Using the Volt-Ohmmeter (ohm mode) check thermal sensor B1 (Output Diodes heat sink) value, shall be 0 Ohms.

  • Page 38: Emi Filter Board Voltage Test

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
  • Page 39 EMI FILTER BOARD VOLTAGE TEST (continued) Input cable Neutral – N L’ & N’ To Main Board Input cable Phase - L TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the SPEEDTEC 215C 2.

  • Page 40: Main Board Voltage Test

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
  • Page 41 MAIN BOARD VOLTAGE TEST (continued) WARNING DO NOT CONNECT THE SAME SCOPE GROUND BETWEEN HIGH SIDE AND LOW SIDE TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the SPEEDTEC 215C 2.
  • Page 42 MAIN BOARD VOLTAGE TEST (continued) WARNING DO NOT CONNECT THE SAME SCOPE GROUND BETWEEN HIGH SIDE AND LOW SIDE X8: Main Board to Control Board connector Pin # Description Value Notes Not used 4,5 – 5,5 V (typical value) Serial communication between UI and Power 4,5 –...

  • Page 43: Led Information

    MAIN BOARD VOLTAGE TEST (continued) V72 (red) V65 (red) V60 (green) V55 (yellow) LED INFORMATION:  V72 (red) = + 15Vdc auxiliary supply present  V65 (red) = lit when inverter is working, it means when voltage is present on output studs ...

  • Page 44: Control Board Test

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact your Local Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
  • Page 45 CONTROL BOARD TEST (continued) LED V7 LED V6 connector connector TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the SPEEDTEC 215C 2. Follow the control board removal procedure ® 3. Apply 115Vac or 230Vac +/- 10% to the SPEEDTEC 215C 4.

  • Page 46: Error Codes

    ERROR CODES Communication Error: Display board can’t communicate with power board. Problem could be wiring between display and power board or socket on display board doesn't have good connection. Number on display shows number of command which display board can not send to power board or cannot receive respond from power board.

  • Page 47: Disassembly Operations

    DISASSEMBLY OPERATIONS EMI FILTER BOARD REMOVAL AND REPLACEMENT PROCEDURE EMI Filter Figure 1 REMOVAL PROCEDURE Necessary tool: 8 mm Nut Driver Phillips screwdriver PH02 ® 1. Remove main input power to the SPEEDTEC 215C 2. Open the right side panel of the machine following the case cover removal procedure. 3.
  • Page 48 DISASSEMBLY OPERATIONS USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE REMOVAL PROCEDURE Necessary tool: 8 mm Nut Driver Phillips screwdriver PH02 2mm Allen wrench Small flat screwdriver ® 1. Remove main input power to the SPEEDTEC 215C ® 2. Using the 8 mm nut driver remove the 4 screws (A) that fix the SPEEDTEC 215C User Interface panel to the front panel of the machine.
  • Page 49 DISASSEMBLY OPERATIONS USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE Use 2 mm Allen Wrench to loosen the screw from the knobs 5. Using a small flat screwdriver lift the two small knobs (A) and remove them. 6. Using a 2 mm Allen Wrench loosen the Allen screw until you’ll be able to remove the bigger knob (B) 7.
  • Page 50 DISASSEMBLY OPERATIONS WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE Figure 1 REMOVAL PROCEDURE Necessary tool: 8 mm Nut Driver Phillips screwdriver PH02 14mm wrench 8 mm wrench ® 1. Remove main input power to the SPEEDTEC 215C 2. Remove the 3 screws (A) and remove the tool box panel from the machine 3.
  • Page 51 DISASSEMBLY OPERATIONS WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE REMOVAL PROCEDURE 9. Locate the polarity change panel inside the tool box (F) 10. Using the 8mm nut driver remove the 3 screws (G+H) that are fixing the change polarity panel 11.
  • Page 52 DISASSEMBLY OPERATIONS FANS REMOVAL AND REPLACEMENT PROCEDURE Figure 1 REMOVAL PROCEDURE Necessary tool: 8 mm Nut Driver Small flathead screwdriver ® 1. Remove main input power to the SPEEDTEC 215C 2. Follow the side case removal procedure available in this Service Manual 3.
  • Page 53 DISASSEMBLY OPERATIONS GAS SOLENOID REMOVAL AND REPLACEMENT PROCEDURE REMOVAL PROCEDURE Necessary tool: 17mm wrench nippers ® 1. Remove main input power to the SPEEDTEC 215C 2. Follow the side case removal procedure available in this Service Manual 3. Remove the plastic tie (A) and disconnect the gas pipe from the gas solenoid 4.
  • Page 54 DISASSEMBLY OPERATIONS MAIN BOARD REMOVAL AND REPLACEMENT PROCEDURE REMOVAL PROCEDURE Necessary tool: Phillips screwdriver PH02 Small flathead screwdriver 2 x 13 mm wrench ® 1. Remove main input power to the SPEEDTEC 215C 2. Follow the side case removal procedure available in this Service Manual 3.
  • Page 55 DISASSEMBLY OPERATIONS MAIN BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) REMOVAL PROCEDURE (continued) 7. Open the tool box door (F) on the left bottom side of the unit to have access to the main board fixing screws that have to be removed. 8.

  • Page 56: Retest After Repair

    RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. Machine input and output Input Voltage Input Current...

  • Page 57: Electrical Schematics

    ELECTRICAL SCHEMATICS ® Block Diagram : SPEEDTEC 215C...
  • Page 58 ELECTRICAL SCHEMATICS EMI Filter Schematic Y030-1...
  • Page 59 ELECTRICAL SCHEMATICS Main Board Schematic Y027. Page 1/2...
  • Page 60 ELECTRICAL SCHEMATICS Main Board Schematic Y027. Page 2/2...
  • Page 61 ELECTRICAL SCHEMATICS Control Board Schematic - Y028-1...
  • Page 62 NOTE...

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50314

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