View Safety Info SVM209-A April, 2011 POWER MIG® 215XT For use with machine code number: 11521 Return to Master TOC View Safety Info View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN MENU 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.
SAFETY Return to Master TOC i i WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause canchemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines The Above For Diesel Engines ARC WELDING can be hazardous.
SAFETY Return to Master TOC Return to Master TOC ii ELECTRIC SHOCK can kill. ARC RAYS can burn. 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. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
SAFETY Return to Master TOC iii 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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. 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 suivantes: 7.
Return to Master TOC Return to Master TOC Return to Master TOC v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC.
Return to Master TOC vi SAFETY 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 surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Return to Master TOC Return to Master TOC Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.
I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC A-1 TABLE OF CONTENTS - INSTALLATION SECTION A-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION Return to Master TOC Return to Section TOC A-2 A-2 TECHNICAL SPECIFICATIONS – POWER MIG® 215XT INPUT – SINGLE PHASE ONLY Standard Voltage/Phase/Frequency 208/230/1/50/60 Hz Input Current @ 170 Amp Rated Output Input Current @ 215 Amp Rated Output (With 115V receptacle loaded to 15A) (With 115V receptacle loaded to 15A) 39/35 Amps 45/41 Amps RATED OUTPUT Duty Cycle 30% 40% 60% Amps 215 Amps 190 Amps 170 Amps Volts at Rated Amperes 22 Volts 23 Volts 24 Volts OUTPUT Return to Master TOC
INSTALLATION Return to Master TOC Return to Section TOC A-3 Read entire installation section before starting installation. WARNING WARNING ELECTRIC SHOCK can kill. ELECTRIC SHOCK can kill. Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC • Do not touch electrically live parts such as output terminals or internal wiring. • Only qualified personnel should perform this installation.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC A-4 INSTALLATION FIGURE A.1 — Dual Voltage Machine Input Connections 50/60 HZ 3. The 208/230 volt 50/60 Hz model Power MIG® is shipped with a 7 ft.(2.1m). input cable and plug connected to the welder. 4. Using the instructions in Figure A.
INSTALLATION Return to Master TOC Return to Section TOC A-5 GUN AND CABLE INSTALLATION 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. WARNING Turn the welder power switch off before installing gun and cable. Return to Master TOC Return to Section TOC 1. Lay the cable out straight.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC A-6 NOTES Power MIG® 215XT A-6
Return to Master TOC B-1 TABLE OF CONTENTS - OPERATION SECTION B-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Section TOC B-2 OPERATION Read entire Operation section before operating the POWER MIG® 215XT. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. Return to Master TOC • Always gloves. Return to Section TOC B-2 wear dry insulating FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-3 OPERATION LIMITATIONS 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 voltage power source with a constant speed wire feeder to form a reliable robust performance welding system.
OPERATION Return to Master TOC Return to Section TOC B-4 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® 215XT is rated to feed .025 through .045" (0.6-1.2 mm) solid or cored electrode sizes.
OPERATION Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-5 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.
OPERATION Return to Master TOC Return to Section TOC B-6 5. Loosen the socket head cap screw that holds the connector bar against the gun bushing. Important: Do not attempt to completely remove the socket head cap screw. 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®]. 6. Remove the outer wire guide, and push the gun bushing out of the wire drive.
OPERATION Return to Master TOC Return to Section TOC B-7 9. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off POWER MIG® 215XT. NOTE: When using Innershield electrode, the gas nozzle may be removed from the insulation on the end of the gun and replaced with the gasless nozzle. This will give improved visibility and eliminate the possibility of the gas nozzle overheating.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC B-8 NOTES Power MIG® 215XT B-8
Return to Master TOC C-1 TABLE OF CONTENTS - ACCESSORIES SECTION C-1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2 Aluminum Feeding Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC C-2 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 Drive Roll Kit Solid Steel .023”-.030” (0.6-0.8 mm) .035” (0.9 mm) .045” (1.2 mm) .035-.045 (0.9-1.2mm) .040 (1.
ACCESSORIES Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC C-3 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 following push pull gun and adapter kit are available.
ACCESSORIES Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC C-4 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 positioned so electrode or tip will not contact metal case or other metal common to work.
Return to Master TOC D-1 TABLE OF CONTENTS - MAINTENANCE SECTION D-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE Return to Master TOC Return to Section TOC D-2 SAFETY PRECAUTIONS • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment • Do not touch electrically hot parts. Return to Master TOC Return to Section TOC GENERAL MAINTENANCE In extremely dusty locations, dirt may clog the air passages causing the welder to run hot.
MAINTENANCE Return to Master TOC LINER REMOVAL AND REPLACEMENT 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 Return to Master TOC Fixed Adjustable Nozzle Nozzle Replacement Size Stencilled Gas Diffuser Gas Diffuser Diameter of Liner Part on End of Part No. Part No.
MAINTENANCE Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC D-4 GUN HANDLE DISASSEMBLY The internal parts of the gun handle may be inspected or serviced if necessary. TABLE D.2 ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES Description The gun handle consists of two halves that are held together with a collar on each end.
MAINTENANCE D-5 FIGURE D.2 - MAJOR COMPONENT LOCATIONS Return to Master TOC Return to Section TOC D-5 1. 2. 3. 4. 5. 6.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC D-6 NOTES Power MIG® 215XT D-6
Return to Master TOC E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2 Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEORY OF OPERATION GAS SOLENOID SPOOL GUN SWITCH WIRE SPEED CONTROL WIRE DRIVE MOTOR 115V CIRCUIT BREAKER RECEPTACLE CONTROL BOARD FAN MOTOR TACH FEEDBACK TAP SELECTOR SWITCH CONTACTOR CONTROL V 27 .
THEORY OF OPERATION GAS SOLENOID SPOOL GUN SWITCH WIRE SPEED CONTROL WIRE DRIVE MOTOR 115V CIRCUIT BREAKER RECEPTACLE CONTROL BOARD FAN MOTOR TACH FEEDBACK CONTACTOR CONTROL V 27 .
THEORY OF OPERATION GAS SOLENOID SPOOL GUN SWITCH WIRE SPEED CONTROL WIRE DRIVE MOTOR 115V CIRCUIT BREAKER RECEPTACLE CONTROL BOARD FAN MOTOR TACH FEEDBACK TAP SELECTOR SWITCH CONTACTOR CONTROL V 27 .8 AC LINE SWITCH TRANSFORMER THERMOSTAT GUN ASSEMBLY OUTPUT DIODE BRIDGE Return to Master TOC + OUTPUT CHOKE POSITIVE TERMINAL OUTPUT CAPACITORS CONTACTOR RECONNECT PANEL OUTPUT BRIDGE THERMOSTAT GUN TRIGGER + Return to Section TOC E-4 FIGURE E.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC E-5 THEORY OF OPERATION E-5 PROTECTIVE DEVICES AND CIRCUITS THERMAL AND OVERLOAD PROTECTION WIREFEED OVERLOAD PROTECTION The Power MIG® 215XT has two built-in protective thermostats that respond to excessive temperatures. One is located on the main transformer.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC E-6 NOTES Power MIG® 215XT E-6
Return to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2 PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Section TOC F-2 TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING 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.
Return to Master TOC Return to Section TOC F-3 TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. Return to Master TOC Return to Section TOC CAUTION Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-4 F-4 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or damage is evident. electrical 1. Contact your local Lincoln 1.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-5 F-5 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS (continued from previous page) 3. Check the gun trigger leads. Leads #324 to #325 should have continuity (zero ohms) when the gun trigger is activated. If not, the gun trigger or cable may be faulty. Check or replace.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC F-6 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Output voltage and wire feed speed 1. Remove the gun assembly. If the 1. Check for “shorts” in the trigger problem is resolved, the gun circuitry within the Power MIG® is present when the gun trigger is assembly is faulty. Repair or 215XT machine.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-7 F-7 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS There is no gas flow when the gun 1. If a spool gun adapter is installed, 1.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-8 F-8 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WIRE FEEDING PROBLEMS Rough wire feeding or the wire will 1. The gun cable may be kinked or twisted. not feed but the drive rolls are turning. 2. Check the drive roll tension and the position of the grooves. 3. Electrode may be rusted or dirty.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-9 F-9 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Poor arc striking with electrode 1. Make sure the settings for wire 1. The output capacitors may be faulty.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-10 F-10 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS The weld bead is narrow or ropy. 1. Make sure the welding proce- 1. Perform the Output Bridge Rectifier Test.
Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST 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.
Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR FIGURE F.1 – OUTPUT SELECTOR SWITCH TERMINALS X2 X3 X4 X5 X6 X7 X8 PROCEDURE 7. Connect main input power to the machine. 8. Turn the Power MIG® 215XT ON/OFF Power Switch to the ON position. WARNING THE ON/OFF POWER SWITCH will be “hot” during these tests. WARNING ELECTRIC SHOCK can kill. NOTE: Secondary voltages will vary proportionately with the primary input voltage. 1. Disconnect the main input power supply to the machine.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-13 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) FIGURE F.2 – LEAD X1 X1 FIGURE F.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-14 MAIN TRANSFORMER TEST (continued) TABLE F.1 – TEST POINTS INPUT VOLTAGE TEST POINTS EXPECTED VOLTAGE READING 230 VAC X1-X2 11.9-13.0 VAC 230 VAC X1-X3 14.1-15.2 VAC 230 VAC X1-X4 16.2-17.5 VAC 230 VAC X1-X5 18.4-19.7 VAC 230 VAC X1-X6 20.5-22.0 VAC 230 VAC X1-X7 22.7-24.2 VAC 230 VAC X1-X8 24.8-26.5 VAC 230 VAC X9-X10 26.9-28.8 VAC 12.
Return to Master TOC Return to Section TOC F-15 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-16 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) FIGURE F.4 – PLUG J4 Black Tach Black Arm White Arm Return to Master TOC Return to Section TOC J11 Red 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.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-17 F-17 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) 5. Make the following voltage tests: TEST FOR SUPPLY VOLTAGE TO TACHOMETER 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. 1. Disconnect the main AC input power to the machine. 2. Locate plug J4. 3.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-18 TROUBLESHOOTING AND REPAIR F-18 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) FIGURE F.5 – PLUG J4 Black Tach Black Arm White Arm J11 Red Tach Blue Tach TEST FOR FEEDBACK VOLTAGE TO CONTROL BOARD Return to Master TOC Return to Section TOC 1. Disconnect the main AC input power to the machine. 2. Locate plug J4 and the tach leads. Figure F.5. EXPECTED VOLTAGE Black (-) BLUE (+) 3.0 TO 4.
Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING AND REPAIR OUTPUT BRIDGE RECTIFIER TEST 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.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-20 F-20 OUTPUT BRIDGE RECTIFIER TEST (continued) FIGURE F.6 – RECTIFIER TEST POINTS t n o Fr + - Return to Master TOC Return to Section TOC Negative Lead 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.
Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING AND REPAIR CONTACTOR TEST 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.
TROUBLESHOOTING AND REPAIR F-22 CONTACTOR TEST (continued) Return to Master TOC Return to Section TOC F-22 FIGURE F.7 – CONTACTOR TERMINALS AND LEADS Return to Master TOC Return to Section TOC 106B 106C 107A Output Contactor Return to Master TOC Return to Section TOC 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. See Figure F.7.
Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING AND REPAIR F-23 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) Return to Master TOC Return to Section TOC 0 volts 10.0V 5ms Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MACHINE LOADED TO 200 AMPS AT 22 VDC This is a typical DC output voltage waveform generated from a properly operating machine.
Return to Master TOC Return to Section TOC F-24 TROUBLESHOOTING AND REPAIR F-24 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”) Return to Master TOC Return to Section TOC 0 volts 1.0 ms Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 20.0V 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 represents 1.0 milliseconds in time.
Return to Master TOC Return to Section TOC F-25 TROUBLESHOOTING AND REPAIR F-25 ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) ONE OUTPUT DIODE NOT FUNCTIONING Return to Master TOC Return to Section TOC 0 volts 5ms 20.0 V Return to Master TOC Return to Section TOC MACHINE LOADED TO 180 AMPS AT 16 VDC This is NOT a typical DC output voltage waveform. One output diode is not functioning. Note the increased ripple content.
Return to Master TOC Return to Section TOC F-26 TROUBLESHOOTING AND REPAIR F-26 ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”) Return to Master TOC Return to Section TOC 0 volts 5ms Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 20.0 V This is NOT a typical DC output voltage waveform. The output capacitors are not functioning. Note the lack of “filtering” in the output waveform.
Return to Master TOC Return to Section TOC F-27 TROUBLESHOOTING AND REPAIR 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.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-28 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.8 – CONTROL BOARD MOUNTING PINS DEPRESS LOCKING TAB ON MOUNTING PIN PROCEDURE 1. Remove power to the machine. 6. Carefully remove the control board. 2. Using a 5/16” nutdriver, remove the three screws securing the tool tray. 7.
Return to Master TOC Return to Section TOC F-29 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR 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.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-30 F-30 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.9 – WIRE DRIVE LOCATION Return to Master TOC Return to Section TOC Wire Drive 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.
Return to Master TOC TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.10 – WIRE DRIVE HOSE & LEAD LOCATION 5/16" Sheet Metal Screws Return to Master TOC Return to Section TOC Return to Section TOC F-31 9/16" Bolt Gas Hose Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FIGURE F.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-32 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) 1. Place the new wire drive assembly into its proper position. 5. Using a 3/4” nut driver, replace the thick black lead previously removed. 2. Connect plug J4. 6. Reconnect the gas hose to the wire drive assembly. 3. Maneuver assembly back into its original position. 7. Close case wrap around cover.
Return to Master TOC Return to Section TOC F-33 TROUBLESHOOTING AND REPAIR OUTPUT DIODE BRIDGE RECTIFIER 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.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 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. Locate the output diode bridge rectifier. See Figure F.12. 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-35 TROUBLESHOOTING AND REPAIR F-35 OUTPUT DIODE BRIDGE RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-36 NOTES Power MIG® 215XT F-36
Return to Master TOC Return to Section TOC F-37 TROUBLESHOOTING AND REPAIR OUTPUT CAPACITORS 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-38 TROUBLESHOOTING AND REPAIR F-38 OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.14 – CAPACITOR BANK LOCATION LOWER RIGHT CASE WRAPAROUND COVER Return to Master TOC Return to Section TOC CAPACITOR BANK ASSEMBLY PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side case wraparound cover. See Figure F.14. 5. Remove the capacitor bank assembly from the machine. 2.
TROUBLESHOOTING AND REPAIR F-39 OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-40 NOTES Power MIG® 215XT F-40
Return to Master TOC Return to Section TOC F-41 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER 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.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-42 F-42 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.16 – MAIN TRANSFORMER LOCATION Main Transformer Return to Master TOC Return to Section TOC 1/2" Mounting Bolts PROCEDURE 1. Using a 3/8” nutdriver, remove both sides of the case wraparound cover. 7. Using a 1/2” nutdriver, label and remove lead X1 from the output diode bridge rectifier. 2.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-43 F-43 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.17 – LEADS X9, X10, 104B, 104C, & H1B 104B 104C X9 X10 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC H1B 15. Carefully maneuver the main transformer out the left side of the machine. 5. Reconnect lead X1 to the output diode bridge rectifier.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-44 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.18 – LEADS SWITCH LEADS X2 X3 X4 X5 X6 X7 X8 Return to Master TOC Return to Section TOC FIGURE F.
Return to Master TOC Return to Section TOC F-45 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.20 – REAR ACCESS PANEL Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 5/16" Nut REAR ACCESS PANEL FIGURE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-46 NOTES Power MIG® 215XT F-46
Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING AND REPAIR FAN BLADE / MOTOR 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.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-48 F-48 FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.22 – FAN MOUNTING BOLTS REAR } Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Fan Motor Fan Mounting Band } Return to Section TOC Fan Blade 11/32" Mounting Nuts 5/16" Bolts PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side of the case wraparound cover. 8.
Return to Master TOC Return to Section TOC F-49 TROUBLESHOOTING AND REPAIR OUTPUT CONTACTOR 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.
Return to Master TOC TROUBLESHOOTING AND REPAIR F-50 OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.23 – OUTPUT CONTACTOR LEADS 106B 106C 107A Return to Master TOC Return to Section TOC Return to Section TOC F-50 Return to Master TOC Return to Section TOC Output Contactor 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.
Return to Master TOC TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC F-51 OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-52 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts/Herts Maximum Idle Amps Maximum Idle Watts 230/60 2.0 150 OPEN CIRCUIT VOLTAGE Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 35 - 40 VDC Return to Section TOC F-52 WIRE SPEED RANGE 50 - 700 IPM (1.27 - 17.
TABLE OF CONTENTS - DIAGRAM SECTION Return to Master TOC G-1 G-1 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram (L12184-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2 Schematic – Complete Machine (L12308-1 PG1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Section TOC G-2 G-2 ElEcTrical DiaGramS WiriNG DiaGram - cOmplETE machiNE - l12184-1 POWER MIG 215XT (208/220/230V) FOR CODE 11521 GENERAL INFORMATION NOTES: ELECTRICAL SYMBOLS PER E1537 N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIVE”. TO CHANGE POLARITY, TURN THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK STUD.
SchEmaTic - cOmplETE machiNE - l12308-1 pG1 ENGINEERING CONTROLLED MANUFACTURER: No CHANGE DETAIL: REVISED PAGE 2. FRONT TOP LEFT 40 VDC 1106A ONLY ON EARLY CODES X9 1114A LOCATEDON 10K POT CASEFRONT ADJUSTSWIRE FEEDSPEED GAS SOLENOID RECTIFIER DIODE BRIDGE 12V 20 OHMCOIL 6VHOLD MOVED TO CONTROL BOARD ON CODE 11099 AND HIGHER + X10 1104D Return to Master TOC Return to Section TOC 1106C 6J1 CONTROL BOARD POWER 14J1 10J1 + 27.
Return to Master TOC G-4 ElEcTrical DiaGramS SchEmaTic - cOmplETE machiNE - l12308-1 pG2 L12308-1 Return to Section TOC G-4 ENGINEERING CONTROLLED MANUFACTURER: No CHANGE DETAIL: REVISED PAGE 2. CONTROLSTHE FUNCTIONALITYOF THEMACHINE 5J1 PTC CONTROL P.C. BOARD THESSTANDARDFEEDMOTORCIRCUIT ALSOISUSEDFORALL THESPOOL GUN MOTORSWHENSELECTEDWITH ADAPTERPANEL.
G-5 ElEcTrical DiaGramS SchEmaTic - cONTrOl bD - G4414 pG1 C33 820pF 50V R67 TACH_SIGNAL 6 P2(5) NC GND 1 3 Q11 0.115A 60V DRIVE_ON DRIVE_ON 20 P2(0) 11 J14 COLD INCH +15V +5V 1 1 R87 2.21K 0.1W L1 600 OHMS CW 10K 2 J14 R110 Return to Master TOC 100K 0.1W 1K 0.063W COM C12 0.1uF 50V 3 D17 0.2A 70V 1 +5V 1.82K 1.82K OCI1 4 100K 0.1W COM 10K 0.1W R145 10K 0.063W 2 R123 100K 0.1W X3 1 100K 0.1W 1 R122 100K 0.1W R91 75K 10 J1 CLUSTER 2 1 +15V 3 D25 +5V 3.32K 0.
+DC_IN C7 0.0047uF 50V R26 1.82K +15V 0.55A 1 1 1 1 OUT POSITIVE_5V +5V 0.5A 200 R39 C3 220uF 25V X5 78M05C GND R38 R49 IN C29 0.1uF 50V R47 R48 1.5K C8 0.1W 100pF 100V C5 220uF 25V 1.5K R28 5.11K 0.1W 100K 0.1W R34 C6 150pF 100V R31 8 4 2 1 3 R32 Return to Master TOC VREF RT/CT VFB X1 COMP 2842AD8 CS C28 0.1uF 50V 4 15W DZ3 18V 0.5W 39.2K 0.1W R50 0.1W 2.21K R23 POSITIVE_15V D2 1A 600V 3 Q1 17A 200V R33 7 VCC 6 OUT 5 GND C2 82uF 35V -DC_IN 2 1A 600V D3 R35 33.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC G-7 G-7 ElEcTrical DiaGramS SchEmaTic - cONTrOl bD - G4414 pG3 VSENSE ISENSE INPUT_VOLTAGE SPOOL_SPOT SPEED_CTRL BURNBACK SC_ISENSE Return to Master TOC Return to Section TOC PEAK_CUR_LIM DATA THERMOSTAT INDICATOR LIGHT SCLK CALIBRATE TRIGGER 24 4 25 3 26 2 27 1 15 13 16 12 19 P0[0] P0[1] P0[2] P0[3] P0[4] P0[5] P0[6] P0[7] P1[0] P1[1] P1[2] P1[3] XRES X2 CY8C27443SX P2[0] P2[1] P2[2] P2[3] P2[4] P2[5]