Home

Lincoln Electric SVM167-A User's Manual

1. 415V 15V 25 50VDC Rs i m ghax DRIVE AND BRAKE ca E Z80K 121K 875K 825K o1w 3 TZIK TK czs fg haz u SIGNAL GENERATION x ET 01 50 15V 5v d 507 RIS g R 01 TK m 8 267 2 92 E 01 E om sp 357 5 Qiw iw V RI3 x Li lg DRIVE ON Y sur 2 GC x gt 27
2. LOW SIDE 200 169 249 LUSTER LUSTER BRAKE ON we PSOL gt EAK_CUR_LIM G4560 MULT R116 Vtom CY8C27443SX 1 GAS FLOW ENABLE 0 PLT FIPS SPOOL GUN DI CLUSTER 5 POWER SOURCE OUTPUT CONTROL GAS FLOW ENABLE TOR LICHT SOLENOID DRIVE 11 P15 CONTACTOR DRIVE CALIBRATE CONTACTOR TOGGLE SWITCH IN SPOOL GUN KIT CONNECT TO FILTERED D VOLTAGE J1 PIN 6 CLUSTER 1 PROGRAMMING USE J14 PIN 14 FOR USE J14 PIN 12 FOR 3 I as CLUSTER INFORMATION ASSEMBLY No CLUSTER No 1 amp 2 NOTE This diagram is for reference only It may not be accurate for all machin
3. G 5 SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11070 03850 PG1 G 6 SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11070 03850 PG2 G 7 SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11070 03850 PG3 G 8 SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11099 11247 G4414 PG1 G 9 SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11099 11247 G4414 PG2 G 10 SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11099 11247 G4414 6 11 NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi layered and are therefore considered to be unserviceable Assembly drawings of these boards are no Return to Master TOC longer provided o 5 o i 9 E 3 Return to Master POWER MIG 215 LINCOLN G 2 ELECTRICAL DIAGRAMS mE WIRING DIAGRAM COMPLETE MACHINE CODE 11070 L11986
4. OJo Fle b S s 0 GENERAL INFORMATION NOTES olo 4 NA WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF ELECTRICAL SYMBOLS PER E1537 eE IMMEDIATE AND FUTURE APPLICATIONS CONTROL BOARD 5 CAVITY NUMBERING SEQUENCE COLOR CODE NB THIS DIAGRAM SHOWS THE ELECTRODE POLARITY POSITIVE TO CHANGE POLARITY TURN COMPONENT SIDE OF P C BOARD B BLACK THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK W WHITE STUD WE NE 7 R RED _ 06000000 v2 999 m E 1 DM 2 INDICATES CONNECTOR CAVITY No RECTIFIER TRANSFORMER ASSEMBLY kk CAVITY THERMOSTAT THERMOSTAT 1103A 8 NUMBERING SEQUENCE ie 1 11048 rM 1104A H 44 NON LEAD SIDE OF CONNECTOR 1105A K 5 J4 TRIGGER n TACHOMETER 1106A es MOTOR SIDE i 1107A T 7 gt 1 4 oO O PA pee poo on 1108A lt 8 O U gt Ji 5 8 PIE 1109A K 9 5 1110A K 10 2 5 2 1109A PN 1111A 11 o WIRE FEED 1112A lt 12 SPEED 1113A 13 1114A K 14 5 5 3 5 1108A 1115A lt 15 1116A lt 16 lt 1106A ng 1114A x 1116A J5 lt dd mere T BRIDGE Y Yy GAS 1040 12 lt 2 SOLENOID al 1105A 9 3 X 27 8V 11066 11060 lt 4 e 1107A di 1104 5 5 17068 x 41058 6 6 lt Eon G JUMPER PLUG 2 19 GU Sen JG INSTALLED FOR Hi NON SPOOL GUN SI
5. 77 CONTROL 1105A ane MOTOR USE 41058 6J5 SOLENOID SPOOL 11168 1 lt 145 GUN DETECT USE 110 40 lt 5J5 GUN TRIGGER BOARD gt 14J1 POWER gt 10 1 gt ON CODE 11099 AND HIGHER FRONT OF DRIVE ROLL AREA 1106C 4J5 u GUN TRIGGER 1104C MAIN LOCATEDON TRANSFORVER INPUT WINDINGS RECTIFIER 1 324 4J6 rm m N C N C 1111A DETECT SIGNAL h r gt 2 gt r 325 T gt 2J6 LOCATED INSIDE pen P 7 4 gt COVPARTIVENT LOCATEDINSIDE OF PC BOARD COMEPHIMENT MOTOR LOCATED ON FRONT OF MACHINES BASE MAIN TRANSFORMER H3 H4 TO SINGLE PHASE SUPPLY LINE w H2 B RECONNECT PANEL LL NATIONAL ELECTRICAL CODE TO GROUND PER LOCATEDON MACHNES LEFT REAR X9 T X8 23 2VAC X7 F H2 a l 20 9VAC X6 256VAC OV NO TRIGGER G 86V TRIGGER 9 OQ 164VAC X4 X3 H LINE LOCATEDON SWITCH MACHINES FRONT LEFT MDWAY x2 x FRONT LEFT 115V 402 X12 E 402A LOCATEDON CASE BACK WTHREAR SELECTOR SWITCH x 401 34 FAN MOTOR MOTOR GEARBOX TACH OH
6. DROP COMPENSATION TPIS lt Riss j ROO 100 01 R156 023 T amp 05 m 40V 60 V 01 R138 m STIK 0 Ra RM RE A iad Ww y 9 050V 50 INCHES PER MINUTE 25 TP12 Ts a z 100 id onse 9 ud 150K IAVERAGE RI RIAL no R127 TO 39K 130K V V Tl X6 T R41 Dl VSENSE x6 7 mm 3 30740 332K TZ Rz SHT 2 R136 R131 st 30740 a 1 30740 E de 01 Sis LL 022 HV 50V So MOAN MAIN MOTOR SPEED ERROR COMPENSATOR 15V TP14 FIB detect R75 gt 1 ZAR TOGGLE SPOOL Elus sn O Cm loiw T82K 40V I pu dl 01 sv WV V V 9 103A MAIN MOTOR SPEED Wes LE MIA ROT RIS T 200 175 SET POIN L 8 A Een R79 SHT 2 1094 50V m C54 01 50 15V i A NE sii 15V 15 8 20 0K gt OW 045V R77 NOMINAL 619 b 01W Td a el V 330740 jn V MAIN PWM CONTROL gt SHT 1 130 0 0K 1 R Gs 01 50 GENERAL INFORMAT
7. A c E T d gt E PX EO KEE 8 wa I D 5 iL TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST continued F 13 DOL J8ISEN 1 DOL J8ISEN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL uono s ol DOL Uonoeg DOL uono s ol uini H DOL uono S F 14 TROUBLESHOOTING AND REPAIR F 14 TABLE F 1 Test Points xem ns X tats va mew Xx muc Return to Section TOC Return to Master TOC vac 184197 VAC 205220VAc xxo 269288VAC o lo 12 If ALL the voltages tested are incorrect 13 If the correct nameplate voltage is being or missing test for correct nameplate applied to the main transformer and one 5 input voltage between the H1 lead at the or more of the secondary voltages are E ON OFF POWER SWITCH to H2 or H3 missing or are incorrect the main trans plz at the reconnect panel Voltage tested former may be faulty Replace elg will vary depending on input voltage con cic nection See Wiring Diagram for test 14 When test is complete replace tool tray 5 point locations case sides and top A If the input voltage test is incorrect check for loose or broken leads between the reconnect panel and the ON OFF POWER SWITCH
8. uunjeH DOL uono s ol uini H DOL Uonoeg uini H DOL Uonoeg ol uini H DOL uono S Return to Section TOC Return to Master TOC Return to Section TOC oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC Return to Master TOC F 37 TROUBLESHOOTING AND REPAIR OUTPUT CAPACITORS REPLACEMENT 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 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the Output Capacitors for repair or replacement MATERIALS NEEDED 3 8 Nutdriver 1 2 Wrench POWER MIG 215 LINCOLN F 37 F 38 TROUBLESHOOTING AND REPAIR F 38 location inside the machine 9 9 OUTPUT CAPACITORS REPLACEMENT Continued PROCEDURE o 9 1 Using 3 8 nutdriver remove the lower right 5 Remove the capacitor b
9. F 11 TROUBLESHOOTING AND REPAIR F 11 MAIN TRANSFORMER TEST 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 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION Return to Section TOC Return to Master TOC This test will determine if the correct voltages are being applied a Applied to the primary windings of the Main Transformers b Induced on the secondary and auxiliary windings of the Main Transformer MATERIALS NEEDED 3 8 Nutdriver 5 16 Nutdriver Volt ohmmeter oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN F 12 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST continued FIGURE F 1 OUTPUT SELECTOR SWITCH TERMINALS x2 X4 X5 x6 X7 xS Return to Section TOC Return to Master TOC Return to Sec
10. C 4 NOTES POWER MIG 215 LINCOLN 5 C 4 DOL J8ISEN 1 DOL J8ISEN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL uono s ol DOL uono s DOL Uonoeg ol uini H DOL uono S Section D TABLE OF CONTENTS Section D MAINTENANCE SECTION 5 O Maintenance 5 5 22 dese beta xe ax ERE Section D Safety Precautions D 2 General Maintenance D 2 2 Drive Rolls and Guide Plates D 2 Contact and Gas Nozzle Installation D 2 Gun Tubes and Nozzles D 2 Gun Cable Cleaning D 2 Liner Removal and Replacement D 3 Gun Handle Disassembly D 4 Accessories and replacement parts for Magnum 250L Gun Cable Assemblies D 4 Major Component Location D 5 Return to Master TOC Q 5 o i 9 E 3 Return to Master POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q
11. Heavy Duty Tapered Tab For Aluminum GAS NOZZLES Fixed Flush Recessed Requires Gas Diffuser As bly Adjustable Slip On Requires Nozzle Insulator As bly Requires Gas Diffuser As bly Gasless Nozzle For Innershield KP2020 6B1 KP2020 7B1 KP2020 1B1 KP2020 2B1 KP2021 1B1 KP2020 2B1 KP2022 5B1 KP2022 6B1 KP2022 1B1 KP2022 2B1 KP2010 5B1 KP1931 1 KP1931 2 KP1931 3 KP1930 1 KP1930 2 KP1930 3 KP2026 3 KP1935 2 KP1935 1 KP2025 1 KP2026 2 KP2026 1 KP1947 1 A 025 030 035 045 035 045 025 030 035 045 3 64 Alum Wire 3 8 1 2 5 8 3 8 1 2 5 8 025 045 1 2 5 8 025 030 035 045 0 6 mm 0 8 mm 0 9 mm 1 2 mm 0 9 mm 1 2 mm 0 6 mm 0 8 mm 0 9 mm 1 2 mm 1 2 mm Alum Wire GUN TUBE ASSEMBLIES A Requires KP2026 1 Gas Diffuser Assembly Standard 60 45 KP2015 1 KP2041 1 Included with POWER MIG 215 POWER MIG 215 LINCOLN D 5 MAINTENANCE 0 5 FIGURE 0 2 MAJOR COMPONENT LOCATIONS Case Front Assembly Rear Panel Assembly Center Assembly Wire Drive Assembly Base amp Power Component Assembly Covers Assembly Return to Section TOC Return to Master TOC O U1 gt Q N Return to Section TOC Return to Master TOC oio OJO Fire c 89 S s 9 Sl amp a g L 5 5 cle
12. Return to Section TOC Return to Master TOC QO O o ao 9 E Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC F 42 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT 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 F 16 See Figure 4 Label and disconnect leads X9 X10 104B amp 104C See Figure F 17 5 Using a flathead screwdriver Label and dis connect lead H1B and other associated lead connected to the same terminal These leads are connected to the ON OFF switch See Figure F 17 6 Using a 7 16 nutdriver Label and discon nect leads X8 X7 X6 X5 X4 X3 amp X2 from the switch assembly Note washer position upon removal See Figure F 18 7 Using a 1 2 nutdriver label and remove lead X1 from the output diode bridge rectifi er 8 Using a 5 16 Nutdriver open the rear access panel See Figure F 20 9 Disconnect lead 118 from the rear access panel See Figure F 21 10 Feed lead 118 toward the inside of the machine 11 Cut any necessary cable ties 12 Remove any necessary wiring harnesses 13 Disconnect lead 121 See Figure F 19 14 Using a 1 2 nutdriver remove the four main transformer mounting bolts and associated washer
13. 25 50V0C 5 2 15 0K l A 5 01 100 3 VSENSE gt str 3 ZK o AN PB PA Diw Yun V a DB 104A i R37 TOGGLE RECTIFIER lt lt R142 RUB _ _ c 3v SMICH THERMOSTAT T DRIVE ON 5 yr 17 121 v o vo 01 T Q IW iW 500 SHT 1 12 SV GUN KIT HIN sar Bueno 135 PB PA 1048 vsl 4 x BRAKE ON 1 0 __ 0 L co 1 ES AN EY a 7 1058 TRANSFORMER THERMOSTAT _ Sod TRIGGER DISABLE TRIGGER INPUTS d 1 aV TO Ole s 15V R il im ISENSE Eli I Di3 MAIN 010 1A MOTOR c 5 325 TPS 30v oig 332K o 2s 6 W EEE ar 1 8 332 243K I TRIGGER RUS iW Gi PEROLA 112A o R62 au 25 50V0C 4 dem So 1 BE ACS_RELEASE A 3 0 05 c dg 2 ozs 221 gt sir 3 51V zm 2 ex V o 1 tc 8 267K 32 6 SV A p 25 267K 16 1A 5 600V 5 SEDE Ed I onsa hiso SPOOL TRIGGER 60 foiw GUN 5 SOLENOID 5 5 m Yes R8 R38 100 TOGGLE Fa Ac SWITCH uw Las a 30 V 05 02 116A IN SPOOL i any 2 32k 40V 16 GUN KIT E s 3 4700pF 01 in V SN J5 1168 xi RIZ TS_DETECT MAIN Hn sd fon am us LE x B ane gt 99 1 soon a an 6 THRE 1A 010
14. B Test the ON OFF POWER SWITCH for proper operation oio OJO Fire CiS S a g L 55 d c Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN amp F 15 TROUBLESHOOTING AND REPAIR F 15 WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST 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 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the Wire Drive Motor and Voltage Feedback circuit are functioning properly MATERIALS NEEDED Return to Section TOC Return to Master TOC 5 16 Nutdriver Volt Ohmmeter oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN F 16 TROUBLESHOOTING AND REPAIR F 16 WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST oio EE c m continue
15. Coupling oio OJO Fire c 89 S 9 a g L cle 5 5 d c NOTE Scope probes connected at Trigger machine output terminals probe to electrode probe to Work Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO c 89 S a g L cle 5 5 d c Return to Section TOC Return to Master TOC F 25 TROUBLESHOOTING AND REPAIR F 25 ABNORMAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED MAX TAP G ONE OUTPUT DIODE NOT FUNCTIONING Na NUL NW 0 Volts mail d wii MACHINE LOADED TO 180 AMPS 16 VDC SCOPE SETTINGS This is NOT a typical DC output voltage waveform One output diode is not func Volts Div 20V Div tioning Note the increased ripple con tent One diode was disconnected to Horizontal Sweep simulate an open or non functioning out put diode Each vertical division repre Coupling sents 20 volts and each horizontal divi sion represents 5 milliseconds in time Trigger The machine was loaded with a resis tance grid bank NOTE Scope probes connected at machine output terminals probe to electrode probe to work POWER MIG 215 LINCOLN amp F 26 TROUBLESHOOTING AND REPAIR F 26 ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FU
16. Oo amp a Bg ELE 5 5 clo 230V 208V L1 L2 FIGURE F 21 REAR ACCESS PANEL CLOSE UP Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN Een NOTES F 46 POWER MIG 215 LINCOLN 5 F 46 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL uono s ol uini H DOL Uonoeg uini H DOL Uonoeg ol uini H DOL uono S Return to Section TOC Return to Master TOC Return to Section TOC oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC Return to Master TOC F 47 TROUBLESHOOTING AND REPAIR FAN BLADE MOTOR REPLACEMENT 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 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing
17. Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN D 6 NOTES POWER MIG 215 LINCOLN 5 D 6 DOL J8ISEN 1 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL uono s ol uini H DOL Uonoeg uini H DOL Uonoeg ol uini H DOL uono S Return to Master TOC Return to Master TOC Q 5 2 i 9 E 3 Return to Master Section E TABLE OF CONTENTS Section E THEORY OF OPERATION SECTION Theory of Operation Section E Input Power Circuit E 2 Input Line Voltage E 2 Main Transformer E 2 Voltage Selector Switch E 2 Baffle Mounted Diode Bridge E 2 Control Circuits E 3 Output Rectification Contactor amp Control Boards E 3 Optional Circuits E 4 Control Board Gun Trigger amp Wire Drive Motor E 4 Protective Devices amp Circuits E 5 Thermal Overload Protection E 5 Wirefeed Overload Protection E 5 FIGURE E 1 THEORY OF OPERATION BLOCK DIAGRAM WIRE GAS SP
18. cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b POWER MIG 215 LINCOLN Return to Master TOC Return to Master TOC 5 o 2 E 5 tc Return to Master TOC SAFETY i D WELDING and CUTTING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area lf 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 Where compressed gases are to be used at the job site special p
19. detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Continued continued from previous page Check the gun trigger leads Leads 324 to 325 should have continuity zero ohms when the gun trigger is activat ed If not the gun trigger or cable may be faulty Check or replace Return to Section TOC Return to Master TOC If a spool gum option kit is installed check to make sure it is set to the normal position if using the POWER MIG 215 built in wire feeder When the gun trigger is activated 1 Make sure the gun cable and 1 Check the output selector and the wire feeds normally but work cables are connected Switch for proper operation and there is no open circuit voltage properly and in good condition good connections Return to Section TOC Return to Master TOC Make sure the output selector 2 Perform the Output Contactor switch is in a good condition position and not between posi tions 3 Perform the 4 Perform the Main Transformer Check the heavy current carry ing leads between the output selector switch output contac tor output bridge rectifier and the output terminals for loose or faulty connections See Wiring Diagram OJO C S a g L 55 d c CAUTION Iffor any reason you do not understand the test procedures or are unable
20. equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical con nections To avoid problems when trou bleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before ATTENTION opening the static Static Sensitive shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame Devices Handle only at Static Safe Workstations If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either con
21. nameplate rating and reconnect panel configuration One of the two thermostats may be open due to machine overheating If the machine operates normally after a cooling off period then check for proper fan operation and ventilation Make certain the machine s duty cycle is not being exceeded 1 3 The POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION Contact Lincoln Electric Service Department 1 888 935 3877 Check the input power switch S1 It may be faulty Check for broken or missing wires at the reconnect panel Perform the Main Transformer The baffle mounted rectifier bridge may be faulty Check and replace if necessary Perform the Check the thermostats and associated leads for loose or faulty connections See the Wiring Diagram internal triggering circuit plugs may be faulty See the Wiring Diagram 5 The control board may be faulty CAUTION 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 POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC F 5 TROUBLESHOOTING AND REPAIR F 5 Troubleshooting Guide see wiring Diagrams for location of specified Observe Safety Guidelines components and for troubleshooting of specific circuits
22. properly for the input voltage being applied Make sure the settings for wire feed speed and voltage are cor rect for the process being used Make sure the electrode polarity is correct for the process being used Check the welding cables and gun for loose or faulty connec tions stuck closed F 6 Observe Safety Guidelines detailed in the beginning of this manual 1 Check for shorts in the trigger circuitry within the POWER MIGG 215 machine See the Wiring Diagram The control board may be faulty Check for loose or faulty con nections on the heavy current carrying leads inside the POWER MIG 215 See the Wiring Diagram The output capacitors may be faulty Check for loose connec tions at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid electrolyte in these capacitors is toxic Avoid contact with any portion of your body 3 The output selector switch may be faulty Check for good con tact and continuity zero ohms through the switch See the Wiring Diagram Perform the Output Contactor Perform the Output Bridge Rectifier Test Main Transformer Perform the Test Output Contacto CAUTION Iffor 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
23. 0 m 12 3 6 m 15 4 5 m 025 030 0 6 0 8 mm TABLE C 2 MAGNUM GUN CONNECTION KIT Optional K466 6 Using the optional K466 6 Magnum Connection kit for the POWER MIG permits use of standard Magnum 200 300 or 400 gun and cable assemblies SPOOL GUN AND ADAPTER KIT K1809 1 The K1809 1includes the Magnum 250SG Spool gun and the adapter kit for connecting the spool gun to the POWER MIG 215 The Adapter Kit provides toggle switch selection between the machine s use with its feeder gun or the spool gun for same polarity welding with different wire and gas processes The kit includes a spool gun adapter module assembly with a single connecting plug and trigger switch a rear gas inlet fitting hose solenoid valve assembly and mounting hardware with installation and operation instructions WARNING Remove all input power to the POWER MIG 215 before installing the Spool Gun and Kit POWER MIG 215 LINCOLN Cs ACCESSORIES MAKING WELD WITH THE SPOOL GUN 5 To return to normal POWER MIG 215 welding ADAPTER KIT AND SPOOL GUN release the spool gun trigger set spool gun selector INSTALLED switch to normal and reset feeder gun voltage pro cedure setting if necessary 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 meta
24. 010 IN_MOT_PWM_CONTROL 8 1 E 0225w 40V MAIN_MOT_PWM_CONTR S a xw 40V SHT 3 6 9 1 THRESH V ST ont V Hi cNTVOLT 3 TP9 F2 8 our RIT Lm TOM 10 121K 10 RESET a R52 01 is 3 sex TISK 01W 8 33K m 13 ge 5 nh 9 01 10 in 1 00M 30740 rc 9010 v s MEN sn z V 70V 267 V 7 1908 2 ACS RELEASE 020 V 024 R16 5 70V TZIK w OV L 01 V Riss 34 681K G 45 SHT 2 THEGER RIO Qa n 771 40V ET mL Saw H 3 isok 8 01 T F 15V FEEDER INT D me ys ue 40V BOARD DETEC is i 02 A2 spoo Ew g 2 lt D EM SHT 3 8 detect RISE 50 2 WIRE 100K 15V ccw A ki 15 0K 50V 01w 8 V V x 1332 m 5 243K E nb E cie 0107 R104 Le SPOOL 619 IK 101 15V a GUN KIT Ed 619 AMPHENOL o PINS R50 gt i E 01W ll G2 fin 2 Sik 8 200k R123 05 21280 D 2 RES REZ RBO 1 30740 TN 1 50V 567K 56K iw lt Bias K SA V 3 20 0K a 014 zm V 120 DA 5 01W 21K 02 50V 20 0K SHT gs vx m 40V gt SHT 2 C y ini m ZU SPOOL GUN MOTOR 1 56 an Dum me 134 I DUTY CYCLE SETPOINT m 4 iu R125 T 750 hr d 01 L us 7 idv Q2 RI33 05 V 750K 01 AVERAGE CURRENT SHT 3 TOGGLE SPOQL MOTOR CURRE
25. 9 E 3 Return Master POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC oio OJO Fire CiS S a g L cle 5 5 d c Return to Section TOC Return to Master TOC Return to Master TOC 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machinery may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped according to feeding problems and function problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests ca
26. Board Troubleshooting Procedures F 3 E Troubleshooting Guide F 4 Test Procedures F 11 Main Transformer Test F 11 Wire Drive Motor and Wire Speed Potentiometer Test F 15 Output Bridge Rectifier Test F 19 Contactor Test F 21 Voltage Waveforms F 23 Component Replacement Procedures F 27 Control Board Replacement F 27 Wire Drive Motor Assembly Replacement F 29 Output Diode Bridge Rectifier Replacement F 33 Output Capacitors Replacement F 37 Main Transformer Replacement F 41 Fan Blade Motor Replacement F 47 Output Contactor Replacement F 49 Retest After Repair F 52 a 2 WARNING R e ELECTRIC SHOCK can kill Never work on the inside of the machine without removing the input power You can receive a life threatening electrical shock if you fail to do this Only qualified technicians should perform installation maintenance and troubleshooting work on the machine o 5 o i
27. MIG 215 LINCOLN F 22 F 23 TROUBLESHOOTING AND REPAIR F 23 TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED MAX TAP G L L et j _ 1 10 0 V 5 ms Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MACHINE LOADED TO 200 AMPS AT 22 VDC SCOPE SETTINGS This is a typical DC output voltage wave form generated from a properly operat Volts Div ing machine Note that each vertical division represents 10 volts and that Horizontal Sweep each horizontal division represents 5 milliseconds in time The machine was Coupling loaded with a resistance grid bank eio OJO C lt S 2 a g L cle 5 5 d c Trigger NOTE Scope probes connected at machine output terminals probe to electrode probe to Work Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN amp F 24 TROUBLESHOOTING AND REPAIR F 24 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM MAX TAP G Return to Section TOC Return to Master TOC 0 Volts Return to Section TOC Return to Master TOC SCOPE SETTINGS This is a typical DC output voltage wave form generated from a properly operat Volts Div 20V Div ing machine Note that each vertical division represents 20 volts and that Horizontal Sweep 1 0 ms Div each horizontal division represents 1 0 milliseconds in time
28. SCHEMAT ONTROL PCB ENGINEER APM REFERENCE PROJECT S NUMBER CRM CO ITED Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual 3 POWER MIG 215
29. The following procedure will aid the technician in removing the Output Contactor for repair or replacement MATERIALS NEEDED 7 16 Wrench 5 16 Nutdriver POWER MIG 215 LINCOLN F 49 F 50 TROUBLESHOOTING AND REPAIR F 50 Bg OUTPUT CONTACTOR REPLACEMENT Continued 3 PROCEDURE o o o2 1 Using a 5 16 nutdriver remove the three 7 Replace output contactor g screws securing the tool tray 51 5 8 Using a 7 16 wrench mount the new output E e 2 Locate the output contactor See Figure contactor in its proper location F 23 9 Reconnect leads 106B 106C amp 107A to 3 Using a 7 16 wrench label and remove the their proper terminals See Wiring Diagram two thick black leads at the top of the output contactor Note lead and washer placement 10 Reconnect the two thick black leads previ for reassembly ously removed from the top of the output contactor 4 Remove lead 107A and note lead place ment See Figure F 23 11 Replace the tool tray using a 5 16 nutdriv er 5 Remove leads 106B and 106C See Figure F 23 6 Using a 7 16 wrench remove the three mounting bolts from the output contactor Note washer positions for replacement Figure F 24 Return to Section TOC Return to Master TOC FIGURE F 23 OUTPUT CONTACTOR LEADS ESL eio OJO Fire c 89 S 2 0 oic a g L 3 a DI cle Output Contactor R
30. WHITE EX 12 PIN CONNECTOR NON LEAD SIDE OF CONNECTOR Y YELLOW J4 TRIGGER LABELS 12 8 TACHOMETER EE 6080000 MOTOR SIDE COMMON 000000 7 12 47559 777 FRAME GROUND LATCH 1 EARTH GROUND VIEW OF CONNECTOR ON PC BOARD 5 8 THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL 56 OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC PRINTIS GOR REFERENCE EQUIPMENT TYPE POWER MIG 215 PAGE 2 OF 2 ONLY COMPONENTS AND DRAWN BY cstuble DOCUMENT CIRCUITRY MAY BE ENGINEER J SKERBEC MACHINE SCHEMATIC NUMBER DIFFERENT MATERIAL APPROVAL PROJECT FROM AN ACTUAL MACHINE pare 1282005 CRM37681 L12308 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual EN 168 SOLID EDGE POWER MIG 215 Return to Section TOC Return to Section TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Return to Master TOC Q 5 o oO gt 9 E 3 tc Return to Master TOC G 6 LINCOLN amp ELECTRIC ELECTRICAL DIAGRAMS SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11070 G3850 PG1
31. and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 8 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts b 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods M while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Exposu
32. cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 i SAFETY ARC RAYS can burn 4 8 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 Headshield and filter lens should co
33. indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims POWER MIG 215 LINCOLN F 3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Q 5 o i 9 E 3 F 4 TROUBLESHOOTING AND REPAIR F 4 Troubleshooting Guide see Wiring Diagrams for location of specified components and for troubleshooting of specific circuits Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident The machine is dead no open 1 circuit voltage and no wire feed when the gun trigger is activated The cooling fan is not running There is no open circuit voltage or wire feed when the gun trigger is activated The cooling fan is running 1 Contact your local OUTPUT PROBLEMS Lincoln Electric authorized field service facility Make certain the input power switch S1 is in the ON position Check the input voltage at the machine The input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input lines Make sure the input voltage is correct and matches the
34. machine feeder and gun It provides gun and wire drive conversion parts to weld with 3 64 1 2 mm aluminum wire 5356 alloy aluminum wire is recommended for best push feeding performance Kit includes drive rolls and wire guide plate for the wire drive liner and two contact tips for the gun along with installation instructions READI REEL ADAPTER K363P The K363P Readi Reel Adapter mounts to the 2 spin dle It is needed to mount the 22 30 Ib Readi Reels DUAL CYLINDER MOUNTING KIT K1702 1 Permits stable side by side mounting of two full size 9 dia x 5 high gas cylinders with no lift loading Simple installation and easy instructions provided Includes upper and lower cylinder supports wheel axles and mounting hardware SMALL SPOOL SPINDLE ADAPTER K468 The K468 spindle adapter allows the use of 8 diame ter small spools ACCESSORIES C 2 ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES The following Magnum 250L gun and cable assemblies are separately available for use with the POWER MIG 215 Each is rated 200 amps 60 duty cycle and is equipped with the integrated connector twist lock trigger connector fixed nozzle and insulator and includes a liner diffuser and contact tips for the wire sizes specified English Wire Metric Wire Part No Size Size K533 1 K533 2 K533 3 K533 4 K533 5 K533 6 Length 10 3 0 m 12 3 6 m 035 045 0 9 1 2 mm 15 4 5 m 10 3
35. rectifier bracket to the bottom of the machine These bolts can be 11 Reconnect leads 104A and 104B previously accessed easily from the bottom of the machine removed See Figure F 13 12 Reconnect the four thick black leads previously labeled and removed using a 1 2 nutdriver Return to Section TOC Return to Master TOC 6 Carefully manipulate the output diode bridge rectifier and the mounting bracket out of the left side of the machine 13 Replace the left side of the case wraparound cover FIGURE F 12 OUTPUT DIODE BRIDGE RECTIFIER LOCATION OUTPUT DIODE BRIDGE RECTIFIER eio OJO Fire C 89 S 2 a g L cle 5 5 d c Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO Fire c 89 S 2 a g L 5 5 cle Return to Section TOC Return to Master TOC F 35 TROUBLESHOOTING AND REPAIR F 35 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT CONTINUED FIGURE F 13 OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET 5 16 Mounting Bracket Mounting Bolts 1 2 Rectifier Mounting Bolts Mounting Bracket POWER MIG 215 LINCOLN NOTES F 36 POWER MIG 215 LINCOLN 5 F 36 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN
36. the gun CONTACTOR WIRE SPEED CONTROL T TRANSFORMER OUTPUT BRIDGE THERMOSTAT THERMOSTAT GUN ASSEMBLY OUTPUT POSITIVE CHORE TERMINAL CAPACITORS NEGATIVE TERMINAL Two self re setting thermostats are included in the trigger circuitry If either of these thermostats would open due to excessive heat the trigger circuit would be interrupted and the machine s output and the wire feed would be disabled The board also contains overload protection circuitry which protects the drive motor from excessive current draw NOTE Unshaded areas of block logic diagrams are the subject of discussion POWER MIG 215 LINCOLN 4 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o oO 2 E 3 tc E 5 THEORY OF PROTECTIVE DEVICES AND CIRCUITS THERMAL AND OVERLOAD PROTECTION The POWER MIG 215 has two built in protective thermostats that respond to excessive temperatures One is located on the main transformer The other 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 The thermostats are self resetting once the mach
37. 1 4 0000 TIT 5 8 LEAD COLOR CODE G 4 COMPONENT VALUE UNITS B BLACK G GREEN O ORANGE R RED U BLUE W WHITE Y YELLOW LABELS x7 COMMON 777 FRAME GROUND EARTH GROUND CAPACITOR MFD VOLTS RESISTOR OHMS WATTS CONNECTOR PIN NUMBERS EX 12 PIN CONNECTOR 12 6 fete 12 LATCH VIEW OF CONNECTOR ON PC BOARD ROPRIETARY amp CONFIDENTIAL TS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC POWER MIG 215 REFERENCE EQUIPMENT TYPE SUBJECT ENGINEER J SKERBEC APPROVED NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual MACHINE SCHEMATIC MATERIAL APPROVAL PROJECT rosion UF De 12 8 2005 7681 DOCUMENT DOCUMENT NUMBER REVISION L12308 A POWER MIG 215 SOLID EDGE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio OJO Fire c 89 S 0 oic a g L 5 5 cle Return to Section TOC Return to Master TOC G 5 ELECTRICAL DIAGRAMS G 5 SCHEMATIC COMPLETE MACHINE CODE 11247 L12308 PG2 LINCOLN B CONTROLS THE CONTROL FUNCTIONALITYOF P C BOARD THE MACHIN
38. 5 i 9 E 3 D 2 SAFETY PRECAUTIONS 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 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 The fan motors have sealed ball bearings which require no service DRIVE ROLLS AND GUIDE PLATES After every coil of wire inspect the wire drive mecha nism Clean it as necessary by blowing with low pres sure compressed air Do not use solvents for cleaning the idle roll because it may wash the lubricant out of the bearing All drive rolls are stamped with the wire sizes they will feed If a wire size other than that stamped on the roll is used the drive roll must be changed For instructions on replacing or changing drive roll see Wire Drive Rolls in Operation section CONTACT TIP AND GAS NOZZLE INSTALLATION 1 Choose the correct size contact tip for the electrode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser 2 Screw the appropriate fixed gas nozzle fully onto the diffuser Either the standard 50 12 7 mm flush nozzle or o
39. 935 3877 POWER MIG 215 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o i 9 E 3 components and for troubleshooting of specific circuits PROBLEMS SYMPTOMS There is no gas flow when the gun trigger is activated The wire feeds and the arc voltage is present The machine stops feeding wire while welding When the gun trig ger is released and pulled again the wire feed starts FUNCTION PROBLEMS Ifa spool gun adapter is installed make certain the toggle switch in the spool gun kit in the correct position 1 a spool gun adapter is NOT installed make certain the jumper plug is installed in J5 See the Wiring Diagram Check the gas source and hoses for kinks or leaks Check for a mechanical restric tion in the wire feed path The gun may be clogged Make sure the drive rolls and guide plates are clean and are the correct size Check the spindle for ease of rotation F7 TROUBLESHOOTING AND REPAIR F 7 Troubleshooting Guide see Wiring Diagrams for location of specified Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION 1 Check plug J1 on the control board for loose or faulty connections See Wiring Diagra
40. CONNECTION t lt 10 V 77 FRAME CONNECTION Oo G m 1 EARTH GROUND CONNECTION o 600v n THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION DWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED P z PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC II COMPONENTS OR CIRCUITRY ON TE BOARD MAY RANDE DESIGN INFORMATION REFERENCE EQUIPMENT TYPE POWER 200 PAGE 02 OF 3 ABILITY OF A COMETE BOARD AWN 0S f I SUBJECI SCHEMATIC CONTROL PCB REVISION m Vv DIAGRAM MAY NOT SHOW THE EXACT ENGINEER LL EU d NUMBER REVISION COMPONENTS OR CIRCUITRY OF CONTROLS MATERIAL APPROVAL PROJECT 2 HAVING COMMON CODE NUMBER APPROVED DRAWING oisposition DATE 08 12 2002 5017743 G 3850 201 A o NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 5 ELECTRIC POWER MIG 215 Return to Section TOC Return to Master TOC Return to Section TOC OJO c 89 S 2 9 a g L 5 5 clo Return to Section TOC Return to Master TOC Return to Master TOC G 8 ELECTRICAL DIAGRAMS SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11070 G3850 PG3 CABLE VOLTAGE
41. E SCHEMATIC G3850 PIC lt SPOOL GAS SOLENOID GUN GAS SOLENOID MOTOR GAS SOLENOID 8VAC 50 INMN 6 PIN LOCATEDON 20VAC 700INMN CASEBAK SPOOLGUN AVPHENOL ADAPTER A MOTOR PANEL MOTOR V B7DCWFENGASISRLOMNG LOCATEDON WFS COIL 21 6 HVS 12VDCCOLL DIVIDERPANEL SPOOL GUN POT INWREDRVE COMPARIMENT TOSWMTCHBEMEEN TOGGLE SPOOL GUNAND SWITCH o o 405C STANDAFDGUN 1050 Lo 405E SPOOL GUN TRIGGER POWER TO STANDARD GAS SOLENODANDUSED 466 FOR SPOOL GUN DETECT AT CONTROL BOARD CLOSING GUN TRIGGER MAKES BOTH 1046 THE STANDARD GUN AND THE SPOOL FROVISTANDARD GUN TRIGGER 406D NOAVALLY CLOSED SHOWN GUNELECTRICALLYHOT 40 104E IN SPOOL GUN POSITION 3 OONTROLS THE TO CONTROL BOARD TRIGGER FUNCTIONALITY OF REFER TO L11543 FOR SPOOL GUN THE MACHINE THERVOSTAT FOR SPOOL GUN OPERATION UNPLUG JUMPER J5 FROM P5 OF MACHINE HARNESS ADAPTER PANEL INSTALLATION AND PLUG IN SPOOL GUN HARNESS INSTRUCTIONS CAVITY NUMBERING SEQUENCE LEAD COLOR CODE COMPONENT VALUE UNITS COMPONENT SIDE OF P C BOARD B BLACK CAPACITOR MEDIVOLTS Horum RESISTOR OHMS WATTS R RED U BLUE CONNECTOR PIN NUMBERS W
42. EED SOLENOID CONTROL WIRE TRANSFORMER OUTPUT BRIDGE THERMOSTAT THERMOSTAT LINE SWITCH TAP SELECTOR SWITCH CONTACTOR CONTROL GUN ASSEMBLY POSITIVE CHOKE TERMINAL CONTACTOR RECONNECT MAIN PANEL TRANSFORMER NEGATIVE TERMINAL POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o i 9 E 3 tc THEORY OF OPERATION FIGURE E 2 INPUT POWER CIRCUIT GAS SOLENOID FAN RECTIFIER DIODE BRIDGE TAP SELECTOR 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 215 through a line switch located on the front panel A reconnect panel allows the user to configure the machine for the desired input voltage The AC input voltage is applied to the primary of the main transformer The cooling fan motor 120VAC is powered from a portion of the primary winding For welding purposes the main transformer converts the high voltage low current input power to a low voltage high current output This tapped secondary winding is coupled to a voltage selector switch By selecting one of seven positions on the s
43. EMATIC CONTROL PCB V DIAGRAM MAY NOT SHOW THE EXACT ENGINEER LL 00 NOT TU NUMBER COMPONENTS OR CIRCUITRY OF CONTROLS MATERIAL 4 HAVING A COMMON CODE NUMBER APPROVED oRAWING oisposirion NA pate 08 12 2002 5017743 G 3850 2D1 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER MIG 215 Gr ELECTRICAL DIAGRAMS e SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11070 G3850 PG2 Im oO S c 8 15V E DRIVE 5 sv E 15 A 105A
44. ER MIG 215 LINCOLN A 6 NOTES POWER MIG 215 LINCOLN 5 A 6 DOL J8ISEN 1 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL uono s ol uini H DOL Uonoeg uini H DOL Uonoeg ol uini H DOL uono S Return to Master TOC Return to Master TOC Q 5 o i 9 E 3 Return to Master one TABLE OF CONTENTS OPERATION SECTION ere recours boa ee Section B Safety Precautions iii B 2 Product Description T B 3 Recommended Processes and Equipment B 3 Weldi g Capabilily Em B 3 M ris S m B 3 Description of Controls u uu Nestes B 3 Wire Drive Poll RR B 3 Wire Size Conversion parts ir B 3 Procedure for Changing Drive Roll B 4 Wire Reel IIIa B 4 Mounting of 10 to 44 lbs Spools nennen nennen B 4 To stant mulie B 4 Feeding Electrode see B 5 Idle Roll Pressure Settings B 5 Wire Drive Configuration si B 5 2 A 6 Avoiding Wire Feeding Problems B 7 Control PE B 7 Input Line Voltage Protection U l B 7 Wire Feed Overload Protection ss B 7 Welding Thermal Overload Protection B 7 POWER MIG 215 LINCOLN Section B Return to Section TOC
45. G AND REPAIR F 10 Troubleshooting Guide see wiring Diagrams for location of specified Observe Safety Guidelines components and for troubleshooting of specific circuits detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS The weld bead is narrow or 1 Make sure the welding proce 1 Perform the Output Bridge Rectifier May have porosity with the elec dures and electrode polarity are trode stubbing into the plate correct for the process being used 2 The output capacitors may be faulty Check for loose connections at the Make certain the shielding gas is capacitors Also check for leaky correct and the flow is proper capacitors Replace if necessary Make sure the weld joint is not WARNING The liquid electrolyte in contaminated these capacitors is toxic Avoid con tact with any portion of your body The contact tip seizes in the gas dif 1 The tip is being over heated due fuser to excessive current and or high duty cycle Alight application of high temper ature anti seize lubricant may be applied to the contact tip threads CAUTION 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 POWER MIG 215 LINCOLN
46. IDLE ROLL PRESSURE SETTING WARNING M ELECTRIC SHOCK can kill Turn the input power OFF at the weld ing power source before installation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Only qualified personnel should perform mainte nance work B 5 OPERATION B 5 The pressure arm controls the amount of force the drive rolls exert on the wire Proper adjustment of both pres sure arm gives the best welding performance For best results set both pressure arms to the same value Set the pressure arm as follows See Figure B 2a Aluminum wires between 1 and 3 Cored wires between 3 and 4 Steel Stainless wires between 4 and 6 Figure B 2a CORED WIRES SOLID WRES OUTERSHIELD ALUMINUM METAL SHIELD INNERSHIELD STAINLESS WIRE DRIVE CONFIGURATION See Figure 8 2 Changing the Gun Receiver Bushing WARNING ELECTRIC SHOCK can kill N Turn the input power OFF at the weld ing power source before installation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released e Only qualified p
47. ION ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS DIODES 1A400V UNLESS OTHERWISE SPECIFIED LAST NO USED SEE SHEET 1 SUPPLY VOLTAGE NET O POWER SUPPLY SOURCE POINT COMMON CONNECTION 77 7 FRAME CONNECTION EARTH GROUND CONNECTION PROPRIETARY amp CONFIDENTIAL THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT DUPLICATED COMMUNICATED TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE ABILITY OF COMPLETE BOARD THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER DESIGN INFORMATION REFERENCE EQUIPMENT TYPE POWER MIG 200 PAGE 03 OF 3 DRAWN BY DS Bm DOCUMENT DOCUMENT ce ut ao ner SUBJECT SCHEMATIC CONTROL PCB emos SS NA ARRA 08712 2002 RER sumus G 3050 201 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual POWER MIG 215 Return to Section TOC Return to Section TOC Return to Master TOC oio OJO Fire CiS S Pr o a g L cle 5 5 d c Return to Section TOC Return to Master TOC R
48. IVE TO CHANGE POLARITY TURN COMPONENT SIDE OF P C BOARD B BLACK THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK W WHITE STUD R RED U BLUE ELECTRICAL SYMBOLS PER E1537 CONTROL BOARD Return to Section TOC Return to Master TOC INDICATES CONNECTOR CAVITY No TRANSFORMER THERMOSTAT THERMOSTAT CAVITY E NUMBERING SEQUENCE 1104C Q m NON LEAD SIDE OF CONNECTOR J4 TRIGGER TACHOMETER MOTOR SIDE 1 4 5 8 1109A 1113A WIRE FEED SPEED Return to Section TOC Return to Master TOC 1 GAS bs 3 SOLENOID Lael d JUMPER PLUG FRIGGER J6 INSTALLED FOR is 2 NON SPOOL GUN SINGLE PHASE pls 515 OPERATION O BRIDGE gt D4 325 49 2 gt 2 1111A RECTIFIER Jo ba Da TO SINGLE PHASE SUPPLY LINE CONTACTOR 4 1104D w B TAP SELECTOR SWITCH RECONNECT PANEL Go G POWER TRANSFORMER TO GROUND PER NATIONAL ELECTRICAL CODE oio OJO Fire c 89 S 0 oic a g L cle 55 cle FOR
49. N NOTES F 40 POWER MIG 215 LINCOLN 5 F 40 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL uono s ol uini H DOL Uonoeg uini H DOL Uonoeg ol uini H DOL uono S Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o oO 2 E 3 tc F 41 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT 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 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the Main Transformer for repair or replacement MATERIALS NEEDED 3 8 Nutdriver 7 16 Nutdriver 1 2 Nutdriver 5 16 Nutdriver Flathead Screwdriver POWER MIG 215 LINCOLN F 41
50. NCTIONING MAX TAP G Return to Section TOC Return to Master TOC 0 Volts Return to Section TOC Return to Master TOC SCOPE SETTINGS This is NOT a typical DC output voltage waveform The output capacitors are Volts Div 20V Div not functioning Note the lack of filter ing in the output waveform The output Horizontal Sweep capacitor bank was disconnected Each vertical division represents 20 volts and Coupling eio OJO C lt S 2 a g L cle 5 5 d c each horizontal division represents 5 milliseconds in time Trigger NOTE Scope probes connected at machine output terminals probe to electrode probe to work Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC Return to Master TOC F 27 TROUBLESHOOTING AND REPAIR CONTROL BOARD REPLACEMENT 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 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 throughou
51. NGLE PHASE 1 1 3244 gt 1 gt OPERATION O O BRIDGE r gt 254 325 7 254 1111A H3 H 1 12 D RECTIFIER o J4 ck SUPPLY LINE CONTACTOR FIF TO SINGLE PHASE i 6 220 208V H2 E ESA 230 9 2 w 8 1115A o a B TAP SELECTOR U 4 1101A D RECONNECT n SWITCH B 5 gt 4 1102A ao PANEL NE gt 8 0 4 SWITCH B gt 7 1112A 8 ed M 51 TRANSEORMER WE 8111058 c TO GROUND PER NATIONAL ELECTRICAL lt 1 CODE z 2 E 2 2 3 A 4 lt K 5 lt PSY MOTOR GEARBOX 72 D WORK e lt 1 8 gt AAR Q 40 OHMS he tel 588 8 I F E b sls au oO 1 9 A c E L11986 2 tr 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 of the enclosure panels of your machine LINCOLN amp POWER MIG 215 G3 ELECTRICAL DIAGRAMS Ge WIRING DIAGRAM COMPLETE MACHINE CODE 11099 11247 L12184 POWER MIG 215 208 220 230V FOR CODES 11099 AND 11247 GENERAL INFORMATION WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS CAVITY NUMBERING SEQUENCE COLOR CODE B THIS DIAGRAM SHOWS THE ELECTRODE POLARITY POSIT
52. NT SHUTDOWN i 200 332K a 4 V Ww 01 R117 tae FEEDBA K a D y TAVERAGE gt SHT 3 m REN 5 62 340 01 SHT 2 7 SENSE R102 it 9010 gt r2 0 1 01 SHT 2 EM RII 10 0K D17 15V DAY 8 Vv 01 01 V V n id 50 R110 15V 182K V ED EX Fi LAST NO USED GENERAL INFORMATION as m z 5 ELECTRICAL SYMBOLS PER E1537 ba ta t tiw CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS 2 R105 T hs PWM SD DIODES 1A 400V UNLESS OTHERWISE SPECIF SUPPLY VOLTAGE NET 100 x9 1 TY sur 2 2 3 POWER SUPPLY SOURCE POINT n mu 9010 L dL C COMMON CONNECTION sw m sv XR s 7 7 FRAME CONNECTION T 29010 29010 330740 EARTH GROUND CONNECTION ma bu CURRENT SHUTDOWN 7 A 374K n gt m in f THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp CONFIDENTIAL OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC OCCURS AT 20A SINCE COMPONENTS OR CIRCUITRY ON j m M PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION REFERENCE EQUIPMENT TYPE POWER MIG 200 PAGE 01 OF 3 WITHOUT AFFECTING THE INTERCHANGE DRAWN BY DS CENT SEN ABILITY OF A COMPLETE BOARD THIS SUBJECT SCH
53. R IF USED j This screw should only be gently tightened Overtightening will split or collapse the liner and cause poor wire feeding GAS NOZZLE POWER MIG 215 LINCOLN D 4 MAINTENANCE D 4 GUN HANDLE DISASSEMBLY TABLE D 2 ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS Tha intemal paris cof the gua handie may be FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio OJO Fire CiS S a g L cle 5 5 d c Return to Section TOC Return to Master TOC 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 Then pull the collar off the gun handle If the collars are difficult to turn position the gun handle against a corner place a screw driver against the tab on the collar and give the screwdriver a sharp blow to turn the collar past an internal locking rib Counterclockwise GN Description Part No English Size Metric Size CABLE LINER For 15 4 5 m or shorter Cable KP1934 2 KP1934 1 KP1955 1 025 030 035 045 3 64 Alum wire 0 6 0 8 mm 0 9 1 2 mm 1 2 mm Alum wire CONTACT TIPS Standard Duty
54. Return to Master TOC Return to Master TOC o 5 0 gt B tc Return to Master TOC View Safety Info View Safety Info 2 gt 2 o z 2 gt View Safety Info RETURN TO MAIN MENU SVM1 67 A January 2011 POWER 215 For use with machines having Code Numbers 11070 11099 11247 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 THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL LI NCOLN 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 Return to Master TOC Return to Master TOC 5 o 2 E 5 tc Return to Master TOC SAFETY WARNING A CALIFORNIA PROPOSITION 65 WARNINGS 4 Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The Above For Diesel Engines Th
55. Return to Master TOC Return to Section TOC oio OJO Fire CiS S a g L cle 55 d c Return to Section TOC Return to Master TOC Return to Master TOC OPERATION Read entire Operation section before operating the POWER MIG 215 A 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 e Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away 3 x Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion NM Observe all safety information throughout this manual POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC eio OJO c i S 0 oic a g L 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC PRODUCT DESCRIPTION The POWER MIG 215 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 contr
56. Return to Section TOC oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC Return to Master TOC F 29 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT 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 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the Wire Drive and Tachometer for repair or replacement MATERIALS NEEDED 5 16 Nutdriver 9 16 Nutdriver Pliers Small Flathead Screwdriver POWER MIG 215 LINCOLN F 29 F 30 TROUBLESHOOTING AND REPAIR F 30 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Continued FIGURE F 9 WIRE DRIVE LOCATION Return to Section TOC Return to Master TOC Return to Section TOC eio OJO Fire c 89 S 2 oic a g L cle 5 5 clo Return to Section TOC Return to Master TOC Return to Ma
57. SE ONLY Standard Voltage Phase Frequency Current 170 Amp Rated Output Input Current 215 Amp Rated Output 208 230 1 50 60 Hz With 115V receptacle loaded to 15A With 115V receptacle loaded to 15A 39 35 Amps 45 41 Amps RATED OUTPUT Amps Volts at Rated Amperes 215 Amps 22 Volts 190 Amps 23 Volts 170 Amps 24 Volts OUTPUT Welding Current Range Maximum Open Circuit Voltage Welding Voltage Range 30 250Amps 35 Volts 13 5 24 Volts RECOMMENDED INPUT WIRE AND FUSE SIZES 75 C Copper Wire 75 C Copper Wire Input Ampere in Conduit in Conduit Input Voltage Fuse or Breaker Rating On AWG IEC Sizes AWG IEC Sizes For lengths For lengths Frequency Hz Size Super Lag Nameplate up to 100 ft exceeding 100 ft 208 50 60 10 6 mm 8 10 mm 230 50 60 10 6 mm 8 10 mm NOTE Use 10 AWG Grounding Wire WIRE SPEED RANGE Wire Speed 50 700 IPM 1 27 17 8 m minute PHYSICAL DIMENSIONS Height Depth Weight 31 79 in 38 78 in 210 Ibs 808 mm 985 mm 95 kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 4 F to 104 F 20 C to 40 C 40 F to 185 F 40 C to 40 C POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO Fire CiS S 2 0 oic a g L 5 5 cle Return to Section TOC Return to Master TOC A 3 Read entire installation section before starting
58. SPOOL GUN OPTION C1ANDC2 31 000MFD 50 R F FILTER E L12184PRINT Return to Section TOC Return to Master TOC 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 LINCOLN 5 POWER MIG 215 Return to Section TOC Return to Master TOC Return to Section TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Return to Master TOC Q 5 o gt 9 E 3 tc G 4 SCHEMATIC COMPLETE MACHINE CODE 11247 L12308 PG1 LINCOLN B 808711 EN 168 ELECTRICAL DIAGRAMS ENGINEERING CONTROLLED CHANGE DETAIL NEW MANUFACTURER No ON CODE 11099 AND HIGHER FROM X10 39 25VDC lt 100 lt lt CONTROL P C BOARD SCHEMATIC G3850 COM CONTACTOR CONTROLS THE 4A RECTIFIER DIODE BRIDGE MOVED TO CONTROL BOARD ON CODE 11099 AND HIGHER X10 1106B LOCATEDON FUNCTIONALITY OF THE MACHINE CASE FRONT ADJUSTS WIRE FEED SPEED LOCATED INSIDE OF PC GAS SOLENOID com TOP LEFT FRONT OF WELDER SPOOL GUN 12V 20 0HMCOL 6VHOLD SOLENOID OPEN 36 5VDC LOCATED ONRGHT CASEBACK LOCATEDINPC BOARD
59. Ser 50V ue 30v ii PA ye 25 104C 1084 TOGGLE O ca TRIG our 5 lt R I x SWITCH RESE 82V IRSF3011L IN SPOOL T sov RESET W GUN KIT O ra 5550 021 E V BAFFLE MOUNTED 4254 RECTIFIER c 15V 25 50VDC PA PB DIODE L 4 BRIDGE 4 V n 425 50VDC PI o olt RESET 5 2 ioc 8 10 0K E 106A gt foiw 107 1068 7 CONTACTOR 9 UM Le c c 11 6 uid 05A als Ed CONTACTOR GAS SOLENOID CIRCUIT gt lt 15V 5 LOCATE THE PROGRAMMING RESISTORS NEAR s THE FEEDBACK PIN USING SHORT LEADS Fone 50 C gt 25 50V0C A KEEP FEEDBACK WIRING T AWAY FROM INDUCTOR FLUX BTS i j T 106A m se xt 4 25 50V0C 1 0075 Ass INPUT FROM BAFFLE MOUNTED BRIDGE RECTIFIER a amp 4 128 GND m TEN SW 1A 600V 1900 1 1000 h 3 ha Vdd Vec Vec amp p ET GENERAL INFORMATION ELE xs w oO EM 50 B 01 ELECTRICAL SYMBOLS PER E1537 SEE SHEET 1 2113 213 50 ss60 xx ue a m CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED O 114A I na 7 RESISTORS Ohms 1 4W UNLESS OTHERWISE SPECIFIED LABELS gt V A ximiximixizsix DIODES 1A 400V UNLESS OTHERWISE SPECIFIED SUPPLY VOLTAGE NET 10 G gt n HEAVY LINES MUST BE KEPT SHORT AND USE POWER SUPPLY SOURCE POINT olo GROUND PLANE CONSTRUCTION FOR BEST RESULTS 9 s SJ COMMON
60. T ON THE CAGE NOT THE WELDING ELECTRODE 10 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle 2 IN O D SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR GROOVES READI REEL INSIDE CAGE WIRES RELEASE BAR FIGURE B 1 To Mount 10 to 44 Lb 4 5 20 kg Spools 2 300 mm Diameter or 14Lb 6 Kg Innershield Coils For 13 14 Ib 6 Kg Innershield coils a K435 Coil Adapter must be used 1 Open the Wire Drive Compartment Door 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 3 Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the back side of the spool Note an arrow mark on the spindle lines up with the brake holding pin to assist in lining up a hole Be cer tain the wire comes off the reel in a direction so as to de reel from the top of the coil 4 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining ring groove on the spindle 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 POWER MIG LINCOLN Return to Section TOC Return to Master TOC Return to Sec
61. TTEN Ci INC BAL EQUIPMENT TYPE COMMON WIREDRIVE CONTROL SUBJECT SCHEMATIC CONTROL PCB DENT M APPROVAL PROJECT NA NUMBER Return Section Return to Master NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 5 POWER MIG 215 G 11 ELECTRICAL DIAGRAMS ou SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11099 11247 G4414 PG3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC VSENSE ISENSE 24 poto 210120 E on INPUT VOLTAGE BRAKE_ON GAS_ON_OFF SPOOL_SPOT COLD_INCH GAS_PURGE BU TACH SIBNAL SC_ISENS SPOOL GUN DETECT PEAK CUR LIM TRGR INTRLK EN DATA THERMOSTAT INDICATOR LIGHT 16 1 L gt 6 15 DS SCLK CALIBRATE 12 pix A 2 4_0UT 9 8 211435 L TRIGGER i DS soso MOTOR SELECT XRES CLUSTER 1 oio OJO Fire CiS S a g L 5 5 d c LAST NO USE GENERAL INFORMATION a SEE PAGE 1 LABELS A SUPPLY v PROPRIETARY amp CONFIDENT E F DESIGN INFORMATION EQUIPMENT TYPE COMMON WIREDRIVE CONTROL WITHOUT 7 10 2008 SUBJECT
62. VS 1 51085 R Bd TOROID 1 TURN 5VDC TACH SUPPLY 1 8 VDC 50 INMN U L lt 3J4 TACH SIGNAL 265 VDC 700 INMN B lt 4J4 TACH COM B TOR 5 TO 6V ANY SPEED B TO U 35V ANY SPEED LOCATEDON MACHINES BASE PC BOARD LOCATED INSIDE OFPC BOARD lt 5J4 TOROID LOCATEDINSIDE 1TURN OF PC BOARD SINGLE PHASE COVPARTIVENT SIDE BRIDGE RECTIFIER ous X5 D 18 7VAC TAP G 36 0VDC CONTACTOR NORMALLY OPEN 9 14 1VAC RATED 300A TAP F 32 8VDC TAP E 29 6VDC TAP D 26 5VDC TAP 23 2VDC TAP B 20 0VDC TAP 16 9VDC n cv kl 403 CIRCUT MOTOR BREAKER X12 FAN IS CONTINUOUSLY TOFRONT AIRFLOW LOCATEDON CASEBACK ON WHEN POWER SWITCH IS ON PRINT IS FOR REFERENCE ONLY COMPONENTS AND CIRCUITRY MAY BE DIFFERENT FROM AN ACTUAL MACHINE DESIGN INFORMATION DRAWNBY cstuble 31000 50 BANKOF MO CAPACITORS LOCATED ON BASE IN THE MDDLE OF THE MACHINE OUTPUT CHOKE HO MOLDED OUTPUT STUDS LOCATED ON BASE CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD MOTOR GEARBOX R F FILTER 000000 000000 7 1 4 6 NON LEAD SIDE OF CONNECTOR J4 TRIGGER TACHOMETER MOTOR SIDE
63. WIRE GUIDE POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC eio OJO CiS S a g L cle 5 5 d c Return to Section TOC Return to Master TOC Return to Master TOC B 7 9 When no more welding is to be done close valve on gas oylinder if used momentarily operate gun trigger to release gas pressure and turn off POWER MIGO 215 NOTE When using Innershield electrode the gas nozzle may be removed from the insulation on the end of the gun and replaced with the gas less nozzle This will give improved visibility and eliminate the possibility of the gas nozzle overheating AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures 1 Do not kink or pull cable around sharp corners 2 Keep the gun cable as straight as possible when welding or loading electrode through cable 3 Do not allow dolly wheels or trucks to run over cables 4 Keep cable clean by following maintenance instruc tions 5 Use only clean rust free electrode The Lincoln electrodes have proper surface lubrication 6 Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed 7 Keep wire reel spindle brake tension to minimum required to prevent excess reel over travel which may cause wire loop offs from coil 8 Use proper drive rolls and wire dr
64. al polarity for GMA welding If negative polarity is required interchange the con nection of the two cables located in the wire drive com partment near the front panel The electrode cable which is attached to the wire drive is to be connected to the negative labeled terminal and the work lead which is attached to the work clamp is to be connect ed to the positive labeled terminal POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o i 9 E 3 5 AND CABLE INSTALLATION The Magnum 250L gun and cable provided with the POWER MIG 215 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 1 Lay the cable out straight 2 Unscrew knurled screw on the drive unit front end inside wire feed compartment until tip of screw no longer protrudes into gun opening as seen from front of machine 3 Insert the male end of gun cable into the Gun Adapter casting through opening in front panel Make sure connector is fully inserted and tighten knurled screw 4 Connect the gun trigger connec
65. al qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place POWER MIG 215 LINCOLN RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page ETUR i iv Installation dieu ei Section A Operationen inse PTT Section B AcCessOrleS 2 2 1922 2 E RR Rub Ron dre ee Section C Maintenance 25 2 m xr w sie x Rr erar Section D Th
66. ank assembly from the 9 side case wraparound cover See Figure 14 machine cle 2 2 Locate capacitor bank See Figure F 14 6 Place the new capacitor bank into its proper r CC 3 Label and remove the five leads connected to the capacitor bank using a 1 2 wrench Note T Replace the three 3 8 nuts and lock washers washer position upon removal See Figure previously removed F15 8 Using a 1 2 wrench reconnect the five labeled 4 Using a 3 8 nutdriver remove the three capac leads and associated washers previously itor bank nuts and lock washers from the three removed mounting bolts See Figure F 15 5 9 Replace the lower right side case wraparound cover previously removed 5 2 FIGURE F 14 CAPACITOR BANK LOCATION S E cle LOWER RIGHT 5 9 CASE WRAPAROUND COVER eio OJO Fire C 89 9g Oo a g L 3 a DI cle CAPACITOR BANK ASSEMBLY Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN Return to Section TOC Return to Section TOC Return to Master TOC oio OJO Fire c 89 S 9 a g L 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 39 TROUBLESHOOTING AND REPAIR F 39 OUTPUT CAPACITORS REPLACEMENT Continued FIGURE F 15 MOUNTING SCREW BOLT LOCATIONS Lead Mounting Bolts Lock washers 3 places POWER MIG 215 LINCOL
67. by the stenciling on the exposed side of the drive roll WIRE SIZE CONVERSION PARTS The POWER MIG 215 is rated to feed 025 through 045 0 6 1 2 mm solid or cored electrode sizes The drive roll kits and Magnum 250L gun and cable parts are available to feed different sizes and types of electrodes Sed Accessories Section POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC OJO Fire c 89 100 oic a g L 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS 1 Turn off the power source 2 Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine Lift the cast idle roll assembly and allow it to sit in an upright position 3 Remove the outside wire guide retaining plate by loosening the two large knurled screws 4 Twist the drive roll retaining mechanism to the unlocked position as shown below and remove the drive rolls See Figure B 2 FIGURE B 2 5 Remove the inside wire guide plate 6 Replace the drive rolls and inside wire guide with a set marked for the new wire size NOTE Be sure that the gun liner and contact tip are also sized to match the selected wire size 7 Manually feed the wire from the wire reel over the drive roll groove and through the wire guide and then into the bra
68. ctrode may be rusted or dirty The contact tip may be damaged or not the correct size Check the wire spindle for ease of rotation Make certain the gun is pushed all the way into the gun mount and properly seated Return to Section TOC Return to Master TOC No control of wire feed speed 1 The wire feed speed control may 1 The wire speed control potentiometer Other machine functions are nor be dirty Rotate several times may be faulty Check or replace mal and check if the problem is Normal potentiometer resistance is resolved 10K ohms 2 Perform the Wire Drive Motor and Wire Speed Potentiometer Test 3 The control board may be faulty There is no wire feed when the gun 1 Check for adequate wire supply 1 Perform the trigger is activated Normal open circuit weld voltage is present and 2 If the drive rolls are turning the gas solenoid functions normally check for a mechanical restriction 2 The wire speed control potentiometer in the wire feed path may be faulty Check or replace Normal potentiometer resistance is The gun liner may be clogged 10K ohms Check or replace eio HI C S 2 a g L 55 DI EIX 3 The control board may be faulty If the drive rolls are not turning when the gun trigger is activated contact your local Lincoln Electric Authorized Field Service Facility A CAUTION If for any reason you do not understand the test proced
69. d 5 1 Make the following voltage tests Figure F 4 Plug J4 SS WARNING Tach White 9 e 9 ELECTRIC SHOCK can kill Arm Do not touch electrically live X parts such as output terminals or internal wiring All input power must be electri cally disconnected before pro ceeding a Turn the machine OFF between each test conduct the voltage test olo p b Carefully insert the meter probes into the lead side 5 s of plug J4 See Figure F 4 HE Turn the machine ON and pull the gun trigger t ned Ame trigger 2 the machine pull the gun trigger to Tach Tach ele 55 dc FROM LEAD FROM LEAD FROM LEAD Black White 2 29 VDC Armature Armature varies depend ing on wire feed Lead Lead speed 2 If the voltage to the wire drive motor armature is zero check the wires between plug J4 and the wire drive motor Also check the electrical connector J5 for proper connections and jumper plug See the Wiring Diagram 3 If all wires and connectors are good and the voltage to the drive motor armature is zero the control PC board may be faulty Replace the control PC board 4 If the motor is running at high speed and the arma ture voltage is high and uncontrollable replace the control board oio OJO Fire CiS S 0 oic a g L cle 5 5 cle Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN am
70. driver replace both sides of the case wraparound cover FIGURE F 17 LEADS X9 X10 104B 104C amp H1B POWER MIG 215 LINCOLN F 43 F 44 _ AN gt gt Y P 2 7 7 7 we l FIGURE F 19 LEAD 121 amp 118 POWER MIG 215 LINCOLN 8 ELECTRIC FIGURE F 18 LEADS SWITCH LEADS X3 X4 X5 X6 X2 X7 X8 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT Continued F 44 DOL J8ISEIN 1 DOL J8ISEN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL Uonoeg DOL Uonoeg DOL Uonoeg UNH DOL uonoeg oi F 45 TROUBLESHOOTING AND REPAIR F 45 9 9 MAIN TRANSFORMER REPLACEMENT Continued FIGURE F 20 REAR ACCESS PANEL HE A 2s f 1 c INPUT SUPPLY CONNECTION DIAGRAM le 5 16 Nut REAR glg ACCESS amp E PANEL 2 0 A O 1 gle iz 2 C KU c gt c C gt C gt i gt C gt gt C N 2 Lead 118 eio OJO CiS 2
71. ductive anti static or static dissipative Remove the PC board from the static shield ing bag and place it directly into the equip ment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shielding bag f 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 proper failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always
72. e engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Gasoline Engines ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 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 FOR ENGINE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment ANM 1 8 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running QA 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld may be dangerous ing arc or when the engine is running Stop the engine
73. e l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier i SAFETY iv 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m t
74. ection TOC Return to Master TOC POWER MIG 215 LINCOLN amp NOTES F 18 POWER MIG 215 LINCOLN 5 F 18 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL uono s ol uini H DOL Uonoeg uini H DOL Uonoeg ol uini H DOL uono S Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o oO 2 E 3 tc F 19 TROUBLESHOOTING AND REPAIR OUTPUT BRIDGE RECTIFIER TEST 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 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if a diode is shorted or leaky See the machine waveform section in this manual for normal and abnormal output wave forms MATERIALS NEEDED Analog Volt ohmme
75. ed at 215 amps 22 volts at a 30 duty cycle based on a ten minute cycle time It is capable of higher duty cycles at lower output currents The tapped transformer design makes it well suited for use with most portable or in plant generating systems B OPERATION B 3 LIMITATIONS The output voltage current of the POWER MIG 215 is subject to vary if the input power to the machine varies due to its tapped transformer power topology In some cases an adjustment of WFS preset and or voltage tap selection may be required to accommodate a signifi cant drift in input power DESCRIPTION OF CONTROLS See Figure B 1 1 Power ON OFF Switch Place the lever in the ON position to energize the POWER MIG 215 2 Voltage Control Seven voltage tap selections are provided Labeled A minimum voltage through G maximum voltage It should only be adjusted when not welding The control selection can be preset to the setting specified on the proce dure decal on the inside of the wire compartment door 3 Wire Speed Control This controls the wire feed speed from 50 700 inches per minute 1 2 17 8 m min Wire speed is not affected when changes are made in the voltage control FIGURE B 1 LE WIRE DRIVE ROLL The drive rolls installed with the POWER MIG have two grooves one for 035 0 9mm wire and the other for 045 1 2mm wire Drive roll size is indicated
76. ent passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged y 57 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinde
77. eory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual xm es P487 Series amp P202 H 2 POWER MIG 215 Section A TABLE OF CONTENTS Section A INSTALLATION SECTION 5 O Installation es dew eee beta eee ee E Section Technical Specifications A 2 Safety Precautions A 3 2 Uncrating the POWER MIG 215 A 3 LOCATION eaaa Ska a Ba ann A 3 Input Power Grounding and Connection Diagrams A 3 Output Polarity Connections A 4 Gun and Cable Installation A 5 Shielding Gas A 5 Return to Master TOC Q 5 o i 9 E 3 Return to Master POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO C S 0 oic a g L cle 55 cle Return to Section TOC Return to Master TOC A 2 INSTALLATION A 2 TECHNICAL SPECIFICATIONS POWER MIG 215 INPUT SINGLE PHA
78. ersonnel should perform mainte nance work Tools required 1 4 hex key wrench NOTE Some gun bushings do not require the use of the thumb screw 1 Turn power off at the welding power source 2 Remove the welding wire from the wire drive 3 Remove the thumb screw from the wire drive 4 Remove the welding gun from the wire drive POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o i 2 9 E 3 tc 5 Loosen the socket head cap screw that holds the 3 connector bar against the gun bushing Important Do not attempt to completely remove the socket head cap screw 6 Remove the outer wire guide and push the gun 4 bushing out of the wire drive Because of the pre cision fit light tapping may be required to remove the gun bushing 7 Disconnect the shielding gas hose from the gun 5 bushing if required 8 Connect the shielding gas hose to the new gun bushing if required 9 Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned 10 Tighten the socket head cap screw ES OPERATION EG Press the trigger to feed the wire electrode through the gun and cable For solid wire cut the elect
79. es covered by this manual CIRCUIT JNTROLS 2MMON CODE NUMBER ENGINEER APPROVED GENERAL INFORMATION OV UNLESS C LE PROPRIET D FOR ANY ASSEMBLY 04415 LABELS CLTAGE NET SOURCE POINT REFERENCE MATERIAL APPROVAL oseostmion pate NUMBER G 4414 200 POWER MIG 215 ELECTRICAL DIAGRAMS G 10 SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11099 11247 G4414 PG2 Return to Section TOC Return to Master TOC PRIMARY _POSITIVE DC_IN POSITIVE_15V 15V 0 55 Return to Section TOC Return to Master TOC 25 75VDC OPERATION UN on OR 20 60VAC 18 N xs gt se sv OPERATION d s 78M05 025 REQ 45V 05 CLUSTER 1 oio OJO Fire CiS S 0 oic a g L cle 5 5 cle UNLESS CTHERWISE SPECIFIED PECIFIED LABELS SUPPLY VOLTAGE NET ROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL NOT TED COMMUNICATED D FOR ANY PURPOSE WITHOUT THE EXPRESS WRI
80. eturn to Master TOC G 9 LINCOLN amp ELECTRIC TOGGLE Bin TR I G G L N GUN HOGER TRIGGER TRIAGE Tce 15V MOTOR_SELECT p ELECTRICAL DIAGRAMS SCHEMATIC COMMON ANALOG WIREDRIVE PC BOARD CODE 11099 11247 G4414 PG1 TRIGGER 16 P12 tr C1G14GW TRIGGR_INTRLK_EN GAS ON OFF TRGR_INTRLK_EN 5 PAT COLD_INCH GAS PURGE GAS_PURGE 2 4 BURNBACK INPUT_ VOLTAGE R65 POWER TO CONTACTOR AND SOLENOIDS 6 AND EN USING AN EXTERNAL BRIDGE RECTIFIER PRIMARY POSITIVE POSITIVE 15V POSITIVE 5V POWER SUPPLY 1K 45v 0063W 15V HI SIDE llvrc PLANE1
81. eturn to Section TOC Return to Master TOC POWER MIG 215 LINCOLN F 51 TROUBLESHOOTING AND REPAIR F 51 OUTPUT CONTACTOR REPLACEMENT Continued FIGURE F 24 OUTPUT CONTACTOR MOUNTING BOLTS Return to Section TOC Return to Master TOC 7 16 Mounting Bolts Return to Section TOC Return to Master TOC My IT oio OJO Fire c 89 S 9 a g L cle 5 5 cle Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN F 52 TROUBLESHOOTING AND REPAIR F 52 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts Herts Maximum Idle Amps Maximum Idle Watts Return to Section TOC Return to Master TOC OPEN CIRCUIT VOLTAGE 35 40 VDC WIRE SPEED RANGE 50 700 IPM 1 27 17 8 m minute Return to Section TOC Return to Master TOC oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN G 1 ELECTRICAL DIAGRAMS G 1 5 TABLE CONTENTS ELECTRICAL DIAGRAMS SECTION o S ELEC Tete ACMI CI RM T SECTION G WIRING DIAGRAM COMPLETE MACHINE CODE 11070 L11986 G 2 E WIRING DIAGRAM COMPLETE MACHINE CODE 11099 11247 L12184 G 3 E SCHEMATIC COMPLETE MACHINE CODE 11247 L12308 1 G 4 cc SCHEMATIC COMPLETE MACHINE CODE 11247 L12308 2
82. heck for loose or faulty connec output contactor and all heavy cur tions on the work and gun cables rent carrying leads See the Wiring Diagram Return to Section TOC Return to Master TOC Make sure the electrode polarity is correct for the welding process 2 Check the output selector switch for being used proper operation and good connec tions Check for rusted or dirty elec trode wire 3 The output capacitors may be faulty Check for loose connections at the Make sure the machine s settings capacitors Also check for leaky and shielding gas are correct for capacitors Replace if necessary the process being used WARNING The liquid electrolyte in these capacitors is toxic Avoid con tact with any portion of your body 4 Perform the Output Bridge Rectifier OJO C S 0 oic a g L 55 cle A CAUTION 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 Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o i 9 E 3 F 10 TROUBLESHOOTIN
83. ine cools sufficiently If the thermostat shutdown is caused by excessive output or duty cycle and the fan is operating normally the power switch may be left on and the reset should occur within a 15 minute period If the fan is not turning or the air intake louver are obstructed then the input power must be removed and the fan problem or air obstruction must be corrected OPERATION E 5 WIREFEED OVERLOAD PROTECTION The POWER MIG 215 has solid state overload protection of the wire drive motor If the motor becomes overloaded the protection circuitry turns off the wire feed speed and gas solenoid Check for proper size tip liner drive rolls and any obstructions or bends in the gun cable Check for any other factors that would impede the wire feeding To resume welding simply pull the trigger There is no circuit breaker to reset as the protection is done with reliable solid state electronics POWER MIG 215 LINCOLN NOTES E 6 POWER MIG 215 LINCOLN 5 E 6 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL uono s ol uini H DOL Uonoeg uini H DOL Uonoeg ol uini H DOL uono S Section F TABLE OF CONTENTS Section F TROUBLESHOOTING AND REPAIR SECTION 5 Troubleshooting and Repair Section F How to Use Troubleshooting Guide F 2 PC
84. installation SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation 9 Only personnel that have read and under stood the POWER MIG 215 Operating Manual should install and operate this equipment Machine must be grounded per any national local or other applicable electri cal codes The POWER MIG power switch is to be in the OFF position when installing work cable and gun and when connecting other equipment UNCRATING THE POWER MIG 215 Cut banding and lift off cardboard carton Cut banding holding the machine to the skid Remove foam and corrugated packing material Untape accessories from Gas Bottle Platform Unscrew the two wood screws at the Gas Bottle Platform holding the machine to the skid 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 smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air pas sages and cause overheating INSTALLATION A 3 INPUT POWER GROUNDING AND CONNECTION DIAGRAMS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring 0 All input power must be electrically dis connected before proceeding 1 Before sta
85. ion de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement d
86. ive Roll Kits cei suan RR ee wau s ee C 2 3 64 1 2mm Aluminum Feeding Kit K1703 1 C 2 2 Readi Reel Adapter K363P C 2 Dual Cylinder Mounting Kit K1702 1 C 2 Small Spool Spindle Adapter K468 C 2 Alternative Magnum GMAW Gun and Cable Assemblies C 2 Magnum Gun Connection Kit K466 6 C 2 Spool Gun and Adapter Kit K1809 1 C 2 Making a Weld with the Spool Gun Adapter Kit C 3 Return to Master TOC Q 5 o i 9 E 3 Return to Master POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC OJO c 89 S 0 oic a g L 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC C 2 DRIVE ROLL KITS Refer to Table C 1 for various drive roll kits that are available for the POWER MIG 215 The item in Bold is supplied standard with the POWER MIG 215 _ 023 030 0 6 0 8 mm oe 035 0 9 mm 045 1 2 mm 1696 0305 1696 0355 1696 0455 035 0 9 KP1697 035C 045 1 2 mm KP1697 045C KP1695 3 64A TABLE C 1 3 64 1 2 mm ALUMINUM FEEDING KIT K1703 1 This kit helps push feeding aluminum through standard
87. ive idle roll pres sure for wire size and type being used FAN CONTROL The fan is designed to come on when input power is applied to the POWER MIG 215 and go off when power is removed OPERATION B 7 INPUT LINE VOLTAGE VARIATIONS High Line Voltage 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 Voltage You may not be able to get max imum output from the machine if the line voltage is less than rated input The unit will continue to weld but the output may be less than normal for a given tap setting If your input line is low you may want to select a high er voltage tap than given on the recommended proce dure chart WIRE FEED OVERLOAD PROTECTION The POWER MIG has solid state overload protection of the wire drive motor If the motor becomes over loaded the protection circuitry turns off the wire feed speed and gas solenoid Check for proper size tip liner and drive rolls for any obstructions or bends in the gun cable and any other factors that would impede the wire feeding to resume welding simply pull the trigger There is no circuit breaker to reset as the pro tection is done with reliable solid state electronics WELDING THERMAL OVERLOAD PROTECTION The POWER MIG 215 has built in protective ther mostats tha
88. l case or other metal common to work Return to Section TOC Return to Master TOC 1 Setting spool gun selector switch to the Normal position and pulling the trigger for the built in feeder gun e Disables spool gun operation and spool gun gas solenoid valve Closing feeder gun trigger starts feeder gun welding and makes both electrodes electrically HOT Return to Section TOC Return to Master TOC 2 Setting spool gun selector switch to the Spool Gun Position and pulling SPOOL GUN Trigger Disables built in feeder gun operation and machine gas solenoid valve Enables spool gun operation and spool gun gas solenoid valve Closing spool gun trigger starts spool gun weld ing and makes both electrodes electrically HOT 3 Operation with POWER MIG 215 Q 5 o oO 2 E 3 tc Turn the POWER MIG 215 input power ON QO O ao 9 E tc e Adjusting the voltage tap control will increase or decrease your welding voltage e Adjusting the wire speed control on the spool gun will increase or decrease the spool gun wire feed speed NOTE Adjusting the wire feed speed control on the POWER MIGO Panel has no affect on the spool gun s wire feed speed 4 Refer to the procedure decal on the POWER MIGG for initial aluminum settings Make a test weld to determine the final settings Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN
89. l position 11 Replace the two 11 32 fan motor mounting nuts and lockwashers 12 Replace the four 5 16 fan assembly mount ing screws in the rear of the machine NOTE Make sure the fan blade is free to rotate when all of the mounting bolts are replaced 19 Perform the Output Capacitor Bank Replacement Procedure 14 Replace the lower right case cover Fan Blade 5 16 Bolts Fan Mounting Band 11 32 Mounting Nuts POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC Return to Master TOC F 49 TROUBLESHOOTING AND REPAIR OUTPUT CONTACTOR REPLACEMENT 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 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION
90. m Check the gas solenoid by discon necting it from leads 108A and 116A amp B Apply a 12VDC external supply to the solenoid If the sole noid does NOT activate then it may be faulty Replace Check the motor armature current Normal armature current is 2 0 to 2 7 amps maximum If the motor arma ture current is normal and the motor continues to shut off the control board may be faulty Replace If the motor armature current is high over 2 7 amps and there are NO restrictions in the wire feeding path then the motor or gearbox may be defective Replace A CAUTION 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 POWER MIG 215 LINCOLN F 8 TROUBLESHOOTING AND REPAIR F 8 Troubleshooting Guide see wiring Diagrams for location of specified Observe Safety Guidelines components and for troubleshooting of specific circuits detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WIRE FEEDING PROBLEMS Rough wire feeding or the wire will 1 The gun cable may be kinked or not feed but the drive rolls are turn twisted ing Return to Section TOC Return to Master TOC Check the drive roll tension and the position of the grooves Ele
91. n be conducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled RECOMMENDED COURSE OF ACTION lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either bad or good If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All the necessary test specifications and repair procedures are described in detail following the troubleshooting guide All electrical test points terminal strips junctions etc can be found on the electrical wiring diagrams and schematics in the Electrical Diagram Section CAUTION 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 POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o oO 2 E 3 tc F 3 TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this
92. n blow out the cable Repeat this procedure until no further dirt comes out If this has been done and feed problems are experienced try liner replacement and refer to trouble shooting section on rough wire feeding POWER MIG 215 LINCOLN D MAINTENANCE Ds 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 Return to Section TOC Return to Master TOC Fixed Adjustable Nozzle Nozzle Replacement Size Stencilled Gas Diffuser Gas Diffuser Liner Part on End of Part No Part No Number Liner Bushing and Stencil and Stencil Diameter of Electrodes Used Return to Section TOC Return to Master TOC oio OJO Fire Cc 89 S 0 oic a g L EJE 5 5 DI cle Return to Section TOC Return to Master TOC 025 030 Steel 0 6 0 8 mm KP1934 2 030 0 8 mm KP2026 3 KP2026 2 035 045 Steel 0 9 1 2 mm 3 64 Aluminum 1 2 mm LINER REMOVAL INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM 250L KP1934 1 KP1955 1 NOTE The variation in cable lengths prevents the interchangeability of liners between guns Once a liner has been cut for a particular gun it should not be installed in another gun unless it can meet the liner cutoff length requirement Liners are shipped with the jacket of the liner extended the proper amount 1 Remo
93. ncoln 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the Contactor is functional MATERIALS NEEDED Return to Section TOC Return to Master TOC 12 VDC Supply Volt Ohmmeter 7 16 Wrench oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o oO 2 E 3 tc F 22 TROUBLESHOOTING AND REPAIR CONTACTOR TEST Continued TEST PROCEDURE 1 Remove the input power to the POWER MIG 215 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 Fig
94. nform to ANSI Z87 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES 3 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 require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi
95. ntactor to the output rectifier bridge This DC welding voltage is filtered by the output capacitors and applied to the output terminals and welding gun Since the output choke is in series with the positive leg of the output rectifier and also in series with the gun and welding load a filtered constant voltage output is applied to the output terminals of the machine NOTE Unshaded areas of block logic diagrams are the subject of discussion POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio OJO Fire c 89 S 9 a g L cle 55 d c Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE E 4 OPTIONAL CIRCUITS GAS SOLENOID RECTIFIER DIODE BRIDGE CONTACTOR CONTROL 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 It also supplies 2 to 29 VDC depending on the wire speed setting to the wire drive motor The control board monitors 0 5VDC signal from the wire speed potentiometer and adjusts the motor speed accordingly The proper armature voltage is then applied to the wire drive motor The drive motor speed is thus controlled which in turn regulates the electrode wire feed speed through
96. ol scheme consisting of continuous full range wire feed speed control and 7 output voltage tap selections provides versatility with ease of use and accuracy Other features include a 2 51 mm O D wire reel spindle with adjustable brake an integral gas cylinder mounting undercarriage an adjustable Argon blend flow regulator with cylinder pressure gauge and inlet hose a 15 ft 8 6 m Magnum 250L GMAW gun and cable with fixed flush nozzle a 7 ft 2 1 m power cable with plug and a 10 ft 8 0 m work cable with clamp Optional Spool Gun and Adapter kit Dual Cylinder Mounting kit and Aluminum Feeding Kit for push feed ing with standard built in feeder are also available RECOMMENDED PROCESSES AND EQUIPMENT The POWER MIG 215 is recommended for GMA welding processes using 10 to 44 Ib 4 5 to 20 kg 2 51 mm 1 0 spools or Readi Reel coils with option al adapter of 025 through 045 0 6 1 2 mm solid steel 035 0 9 mm stainless 3 64 1 2 mm alu minum and 035 0 9 mm 045 1 2 mm Outershield as well as 035 0 9 mm and 045 1 2 mm Innershield self shielding electrodes The POWER MIG is factory equipped to feed 035 0 9 mm electrodes It also includes a 200A 60 duty cycle or 250A 40 duty cycle rated 15 ft 3 6 m GMAW gun and cable assembly equipped for these wire sizes Use of GMAW processes requires a supply of shielding gas WELDING CAPABILITY The POWER MIG 215 is rat
97. ontact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the Output Diode Bridge rectifier for repair or replacement MATERIALS NEEDED 3 8 Nutdriver 1 2 Nutdriver 5 16 Nutdriver POWER MIG 215 LINCOLN F 33 F 34 TROUBLESHOOTING AND REPAIR F 34 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT CONTINUED PROCEDURE 7 Using a 1 2 nutdriver remove the three bolts mounting the bracket to the rectifier The rectifi er is now ready for repair or replacement 2 Locate the output diode bridge rectifier See Figure F 13 Figure F 12 1 Using a 3 8 nutdriver remove the left side of the case wraparound cover Return to Section TOC Return to Master TOC 8 Mount the new rectifier to the mounting bracket 3 Using a 1 2 nutdriver label and remove the four using the three 1 2 bolts thick black leads connected to the rectifier NOTE Be sure to label lead terminals also Take note of washer placement upon removal 9 Carefully manipulate the rectifier and mounting bracket as a one back into the machine to its proper location 4 Label and remove leads 104A and 104B See Wiring Diagram 10 Mount the unit to the bottom of the machine using the four 5 16 mounting bolts previously 5 Using a 5 16 nutdriver locate and remove the removed four bolts mounting the
98. p F 17 TROUBLESHOOTING AND REPAIR F 17 WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST Olio PIg continued 59 TEST FOR FEEDBACK VOLTAGE b Carefully insert the meter probes D gt TO CONTROL BOARD into the lead side of plug J1 See 93 Figure F5 E S 1 Disconnect the main AC input power to amp the machine c Turn the machine ON and pull the cc gun trigger to conduct the voltage 2 Locate plug J1 and the potentiometer test leads See Figure F 5 1113A and EXPECTED 1109 VOLTAGE 3 Connect main input power to the 1109A 1113 A 0 5 VDC machine A WARNING 5 If the O to 5 VDC is present the c E potentiometer circuit is sending the ELECTRIC SHOCK can kill correct feedback signal to the control D Do not touch electrically live PC board Check the leads and plug terminals J1 See the Wiring Diagram c c Sle All input power must be electri 6 If the to 5 VDC is NOT present or ee NS betore pro NOT correct the control PC board is i not receiving the proper feedback voltage from the potentiometer circuit 4 Make the following voltage tests 7 H the leads are okay the potentiometer circuit may be faulty replace the a Turn the machine OFF between potentiometer circuit each test 8 Replace the tool tray FIGURE 5 PLUG J1 1103A oio OJO Fire CiS S 0 oic a g L 5 5 clo 1109A 1113A Return to S
99. re to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source POWER MIG 215 LINCOLN B Return to Master TOC Return to Master TOC 5 o 2 E 5 tc Return to Master TOC ELECTRIC SHOCK can kill 9 8 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in
100. recautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding curr
101. rode within approximately 3 8 10 mm of the end of the contact tip 3 4 20 mm for Outershield When welding with gas turn on the gas supply and set the required flow rate typically 25 35 CFH 12 16 liters min Connect work cable to metal to be welded Work clamp must make good electrical contact to the work The work must also be grounded as stated in Arc Welding Safety Precautions WARNING When using an open arc process it is necessary to use correct eye head and body protection 1 Insert the welding gun into the gun bushing and tighten the thumb screw 6 Position electrode over joint End of electrode may MAKING A WELD be lightly touching the work mE 7 Lower welding helmet close gun trigger and begin 1 Check that the electrode polarity is correct for the welding Hold the gun so the contact tip to work process being used then turn the power switch distance is about 3 8 10 mm 8 4 20 mm for ON Outershield 2 Set desired arc voltage tap and wire speed for the particular electrode wire material type and thick bo cui welding Papius ind Eid end men ness and gas for MIG and Outershield being e gun away MOm ne goSs used Use the Application Chart on the door inside the wire compartment as a quick reference for some common welding procedures Figure B 2b THUMB SCREW CONNECTOR BLOCK SOCKET HEAD CAP SCREW OUTER
102. rs associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 9 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http Awww lincolnelectric com safety for additional safety information POWER MIG 215 LINCOLN B Return to Master TOC Return to Master TOC 5 o 2 E 5 tc Return to Master TOC PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attent
103. rting 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 frequency specified on the welder nameplate Also be sure the planned installation will meet the U S National Electrical Code and local code requirements This welder may be operated from a single phase line or from one phase of a two or three phase line 2 Models that have multiple input voltages specified on the nameplate e g 208 230 are shipped con nected for the highest voltage If the welder is to be operated on lower voltage it must be reconnected according to the instructions in Figure A 1 for dual voltage machines WARNING Make certain that the input power is electrically disconnected before removing the screw on the reconnect panel access cover POWER MIG 215 LINCOLN A 4 INSTALLATION A 4 FIGURE A 1 Dual Voltage Machine Input Connections INPUT SUPPLY CONNECTION DIAGRAM Connect transformer Return to Master TOC Return to Master TOC 5 o 9 E 3 tc Return to Master TOC Disconnect input power before inspecting or servicing machine Do not operate with covers removed ELECTRIC SHOCK CAN KILL Do touch electrically live parts use or service this equipment Install and Ground machine per National Electrical Code and local codes Use Grounding Stud or Lug inside U
104. s See Figure F 16 FIGURE F 16 MAIN TRANSFORMER LOCATION Main Transformer 1 2 Mounting Bolts POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio OJO Fire c 89 S a g L 3 a DI cle Return to Section TOC Return to Master TOC F 43 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT Continued 15 Carefully maneuver the main transformer out the left side of the machine NOTE Two people may be needed to maneu ver the main transformer out of the machine REPLACEMENT 1 Carefully maneuver the new main trans former back into the machine and onto its mounting studs 2 Using a 1 2 nutdriver mount the main trans former in its proper position 3 Reconnect leads 118 and 121 previously removed 4 Using a 5 16 nutdriver close the rear access panel previously opened 5 10 11 Reconnect lead X1 to the output diode bridge rectifier Reconnect leads X8 X7 X6 X5 X4 X3 amp X2 previously removed from the switch assembly Reconnect lead H1B and the other associat ed lead connected to the same terminal These leads are connected to the ON OFF switch Replace any necessary cable ties and wiring harnesses Reconnect leads X9 X10 104B amp 104C See Wiring Diagram Using a 5 16 nutdriver replace the tool tray Using a 3 8 nut
105. se CU wire only Consult Instruction Manual before insiqlling or operqting 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 National Electrical Code and any applicable local codes See Technical Specifications at the beginning of this chapter for proper wire sizes For long runs over 100 feet larg er copper wires should be used Fuse the two hot lines with super lag type fuses as shown in the fol lowing diagram The center contact in the receptacle is for the grounding connection 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 inserted into a grounded receptacle FIGURE A 2 Receptacle Diagram CONNECT TO A SYSTEM GROUNDING WIRE SEE THE UNITED STATES NATIONAL ELECTRICAL CODE AND OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUNDING CONNECT TO HOT WIRES OF A THREE WIRE SINGLE PHASE SYSTEM Only qualified persons should install SINGLE PHASE 60 HZ input lead for desired voltage 230 V 208 V OUTPUT POLARITY CONNECTIONS The welder as shipped from the factory is connected for electrode positive polarity This is the norm
106. ss bushing of the gun and cable assembly 8 Replace the outside wire guide retaining plate by tightening the two large knurled screws Reposition the adjustable pressure arm to its original position to apply pressure Adjust pressure as necessary WIRE REEL LOADING READI REELS SPOOLS OR COILS To Mount a 30 Lb 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter 1 Open the Wire Drive Compartment Door 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 3 Place the Optional Adapter on the spindle 4 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining ring groove on the spindle 5 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 54 OPERATION ET 6 Position the Readi Reel so that it will rotate in a direction when feeding so as to be de reeled from top of the coil 7 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 8 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 9 Slide cage all the way onto the adapter until the retaining spring pops up fully A CAUTION CHECK TO BE SURE THE RETAINING SPRING HAS FULLY RETURNED TO THE LOCKING POSITION AND HAS SECURELY LOCKED THE READI REEL CAGE IN PLACE RETAINING SPRING MUST RES
107. ster TOC PROCEDURE Remove power to the machine Lift cover to gain access to the wire drive See Figure F 9 Using a pair of pliers disconnect the gas hose from the bottom of the wire drive See Figure F 10 Using a 9 16 nut driver remove the thick black positive lead located just above the gas hose See Figure F 10 NOTE Disconnect lead from the wire drive motor assembly not the machine Wire Drive Using a 5 16 nutdriver remove the three mounting screws next to the wire drive assembly See Figure F 10 Using a 5 16 nutdriver remove the two screws on the case front assembly Figure F 11 Carefully maneuver the wire drive assem bly out the side of the machine to gain access to plug J4 See Wiring Diagram 8 Disconnect plug J4 POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO Fire c 89 a g L 3 a clo Return to Section TOC Return to Master TOC F 31 TROUBLESHOOTING AND REPAIR F 31 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Continued FIGURE F 10 WIRE DRIVE HOSE amp LEAD LOCATION 5 16 Sheet Metal Screws 9 16 Bolt Gas Hose 5 16 N Monuting Screws F DN FIGURE F 11 MOUNTING SCREW LOCATIONS POWER MIG 215 LINCOLN Return to Section TOC Return to Ma
108. ster TOC Return to Section TOC oio OJO Fire CiS S 0 oic a g L 5 5 cle Return to Section TOC Return to Master TOC Return to Master TOC F 32 1 TROUBLESHOOTING AND REPAIR F 32 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Continued proper position Place the new wire drive assembly into its 5 2 Connect plug J4 6 3 Maneuver assembly back into its original position 7 4 Replace all mounting screws previously removed Using a 3 4 nut driver replace the thick black lead previously removed Reconnect the gas hose to the wire drive assembly Close case wrap around cover POWER MIG 215 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC oio OJO Fire CiS S a g L 5 5 d c Return to Section TOC Return to Master TOC Return to Master TOC F 33 TROUBLESHOOTING AND REPAIR OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT 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 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely c
109. t 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 The thermostats auto matically reset when the temperature reaches a safe operating level and welding and feeding are allowed again when gun is retriggered PROCEDURE CHART Wire Feed Speed Voltage Tap Settings Wire Dia Gas Wire Type Polarity 18 gage 16 gage 14 gage 12 gaget0gage 3 16 14 5 16 3 8 1 2 Outershield 1 CTWDt 75Ar 25CO5 10050002 75Ar 25CO Innershield 5 8 CTWDt NoneReq d NR 211MP NoneReq d NR 211MP NoneReq d NR212 T Contact Tip to Work Distance Note Requires Multiple Pass db i 50 B 70 B 80 B 40 B 50 B 60 B 350 F 500 G 500 G 350 F 500 G 200 E 225 F 250 G 250 G 250 9 90 C 90 C 110 D 110 D 150 E 150 E 035 amp 045 NR 211 MP are only recommended for a maximum steel thickness of 5 16 POWER MIG 215 LINCOLN B 8 NOTES POWER MIG 215 LINCOLN 5 B 8 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN 1 DOL J8ISEIN uunjeH DOL uono s ol uini H DOL Uonoeg uini H DOL Uonoeg ol uini H DOL uono S Section C TABLE OF CONTENTS Section C ACCESSORIES SECTION 5 O ACCeSSOrleS Section Dr
110. t this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION The following procedure will aid the technician in removing the Control Board for replacement MATERIALS NEEDED 5 16 Nutdriver POWER MIG 215 LINCOLN F 27 Return to Section TOC Return to Master TOC Return to Section TOC OJO Fire c 89 S 2 a g L 3 a DI EIX Return to Section TOC Return to Master TOC Return to Master TOC F 28 TROUBLESHOOTING AND REPAIR F 28 CONTROL BOARD REPLACEMENT 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 connected to the control board 5 Depress the retaining pins on the sides of the four nylon mounts to release the control board See Figure F 8 Carefully remove the control board Mount the new board to the nylon mounting pins Reconnect any plugs or leads previously removed Replace the tool tray previously removed FIGURE F 8 CONTROL BOARD MOUNTING PINS DEPRESS LOCKING TAB ON MOUNTING PIN POWER MIG 215 LINCOLN amp Return to Section TOC Return to Master TOC
111. ter or Diode Tester 3 8 Nutdriver 1 2 Nutdriver POWER MIG 215 LINCOLN F 19 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio OJO Fire c 89 S s 9 a g L cle 5 5 cle Return to Section TOC Return to Master TOC F 20 TROUBLESHOOTING AND REPAIR OUTPUT BRIDGE RECTIFIER TEST continued TEST PROCEDURE 1 Remove input power to the POWER MIG 215 machine Using the 3 8 nutdriver remove the left case side Locate and disconnect the negative lead from the output rectifier bridge assembly Be sure there is no electrical contact between the rectifier and the lead See Figure F 6 NOTE Do not disassemble the rectifier assembly 4 Test for shorted or leaky diodes by checking from the anodes to the cathodes of the diode heatsink plates The readings should be high resistance in one polarity and low resistance in the opposite polarity If any of the diodes are leaky or shorted the output rectifier assembly should be replaced When the test is complete replace the negative output lead previously removed 7 Replace the left case side Figure F 6 Rectifier Test Points Negative Lead POWER MIG 215 LINCOLN amp F 20 F 21 TROUBLESHOOTING AND REPAIR F 21 CONTACTOR TEST WARNING Service and repair should only be performed by Li
112. the Fan Blade and Fan Motor for repair or replacement MATERIALS NEEDED 3 8 Nutdriver 5 16 Nutdriver 11 32 Open End Wrench Flathead Screwdriver POWER MIG 215 LINCOLN F 47 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o i 9 E 3 tc F 48 TROUBLESHOOTING AND REPAIR FAN BLADE MOTOR REPLACEMENT Continued PROCEDURE 1 Using a 3 8 nutdriver remove the lower right side of the case wraparound cover 2 Perform the Output Capacitor Bank Removal Procedure 3 Using a 5 16 nutdriver remove the four fan mounting screws from the rear of the machine See Figure 22 4 Using an open end 11 32 wrench remove the two fan motor mounting nuts and lock washers See Figure F 22 5 Using a flathead screwdriver loosen the fan blade mounting band See Figure F 22 6 Pry the fan blade off of the mounting shaft NOTE If fan blade cracks or breaks upon removal replace it 7 Carefully manuver the fan motor and fan blade out of the right side of the machine FIGURE F 22 FAN MOUNTING BOLTS HEAR INPUT SUPPLY CONNECTION DIAGRAM F 48 8 Replace the fan motor and fan blade if nec essary 9 Tighten the fan blade mounting band 10 Carefully manuver the fan assembly into its origina
113. ther optional flush or recessed spray arc nozzle sizes may be used See D2 2 in this section MAINTENANCE D 2 3 If using optional adjustable slip on nozzles Table D 2 this section 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 1 0 slip on gas nozzle may be used and should be selected based on the welding application Adjust the gas nozzle as appropriate for the GMAW process to be used Typically the con tact tip end should be flush to 12 3 2 mm extended for the short circuiting transfer process and 12 3 2 mm recessed for spray transfer GUN TUBES AND NOZZLES 1 Replace worn contact tips as required 2 Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required GUN CABLE CLEANING To help prevent feeding problems clean cable liner after using approximately 300 pounds 136 kg of elec trode Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using an air hose and only partial pressure gently blow out the cable liner from the gas diffuser end CAUTION Excessive pressure at the beginning of the clean ing procedure may cause the dirt to form a plug Flex the cable over its entire length and agai
114. tion TOC Return to Master TOC TEST PROCEDURE 6 leads X9 and X10 WARNING 7 Connect main input power to the THE ON OFF POWER SWITCH will be machine not during deste 8 Turn the POWER MIG 215 ON OFF NOTE Secondary voltages will vary Power Switch to the ON position voto MEN ca input voltage WARNING MEM 9 ELECTRIC SHOCK can kill Disconnect the main input power Do not touch electrically live supply to the machine parts such as output terminals or internal wiring oio OJO Fire c 89 S 0 oic a g L 3 a DI cle 2 Remove the case top and side panels Ali input power must be electri with a 3 8 nutdriver cally disconnected before pro ceeding 3 Remove the tool tray with a 5 16 nut driver 9 Carefully make the following voltage tests Table F 1 4 Locate leads X2 thru X8 located on the output selector switch See Figure F 1 10 Turn off the machine 11 If any of the voltages are incorrect 5 Locate lead X1 located on the output PL check Tor lone ar broken connections between the main recif y FAURE See Figure transformer the test points Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN amp F 13 5 E gt lt 2 lt o s GRUT gt lt u
115. tion TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o i 9 E 3 tc FEEDING WIRE ELECTRODE WARNING m e When triggering the electrode and drive mechanism are electrically hot relative to work and ground and remain hot several seconds after the gun trigger is released NOTE Check that drive rolls guide plates and gun parts are proper for the wire size and type being used Refer to in Accessories section 1 Turn the Readi Reel or spool until the free end of the electrode is accessible 2 While securely holding the electrode cut off the bent end and straighten the first six inches If the elec trode is not properly straightened it may not feed properly through the wire drive system 3 Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine Lift the cast idle roll assembly and allow it to sit in an upright position Leave the outer wire guide plate installed Manually feed the wire through the incoming guide bushing and through the guide plates over the drive roll groove Push a suf ficient wire length to assure that the wire has fed into the gun and cable assembly without restriction Reposition the adjustable pressure arm to its origi nal position to apply pressure to the wire 4 Press gun trigger to feed the electrode wire through the gun
116. tlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve outlet WARNING Be sure to keep your face away from the valve out let when cracking the valve 4 Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench NOTE If connecting to 100 CO cylinder an additional regulator adapter must be installed between the regulator and cylin der valve If adapter is equipped with a plas tic washer be sure it is seated for connec tion to the CO cylinder 5 Attach one end of the inlet gas hose to the outlet fit ting of the flow regulator the other end to the POWER MIG 215 rear fitting and tighten the union nuts securely with a wrench 6 Before opening the cylinder valve turn the regula tor adjusting knob counterclockwise until the adjust ing spring pressure is released 7 Standing to one side open the cylinder valve slow ly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully WARNING Never stand directly in front of or behind the flow regulator when opening the cylinder valve Always stand to one side 8 The flow regulator is adjustable Adjust it to the flow rate recommended for the procedure and process being used before making the weld AUXILIARY POWER RECEPTACLES 15 Amp 120 Volt Receptacle The receptacles are UL and CSA approved POW
117. to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 POWER MIG 215 LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC QO O ao 9 E tc Return to Section TOC Return to Master TOC Q 5 o i 2 E 3 F 6 TROUBLESHOOTING AND REPAIR Troubleshooting Guide see Wiring Diagrams for location of specified components and for troubleshooting of specific circuits POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION PROBLEMS SYMPTOMS Output voltage and wire feed speed is present when the gun trigger is NOT activated The machines output is low Welds are cold The weld beads are rounded or humped demonstrat ing poor wetting into the plate The machine cannot obtain full rated output of 200 amps at 22VDC The output voltage is continuous 1 The output contactor 1 when the gun trigger is NOT activat ed The wire feed functions normal ly 1 OUTPUT PROBLEMS Continued Remove the gun assembly If the problem is resolved the gun assembly is faulty Repair or replace If the problem is NOT resolved the fault is within the POWER MIG 215 machine Check the input voltage Make sure the machine is configured
118. tor from the gun and cable to the mating receptacle inside the compart ment located above the gun connection made in item 3 above Make sure that the keyways are aligned insert and tighten retaining ring SHIELDING GAS For Gas Metal Arc Welding Processes Customer must provide cylinder of appropriate type shielding gas for the process being used A gas flow regulator for Argon blend gas and an inlet gas hose are factory provided with the POWER MIG 215 When using 100 CO an additional adapter will be required to connect the regulator to the gas bottle A WARNING CYLINDER may explode if damaged Gas under pressure is explosive Always keep gas cylinders in an upright position and always keep chained to undercarriage or stationary support See American National Standard Z 49 1 Safety in Welding and Cutting published by the American Welding Society Install shielding gas supply as follows 1 Set gas cylinder on rear platform of POWER MIG 215 Hook chain in place to secure cylinder to rear of welder INSTALLATION A 5 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the ou
119. ure F 7 See the Wiring Diagram 4 Using the 7 16 wrench remove one lead from the contactors large terminals See Figure F 7 See the Wiring Diagram 5 Carefully apply 12 VDC to the contactor coil leads small terminals Do not leave the 12 VDC applied to the contactor coil for a prolonged period of time 15 seconds maximum Damage to contactor may result 6 If the contactor does not activate when the 12VDC is applied the contactor is faulty Replace 7 If the contactor activates when the 12VDC is applied check the resistance between the two large terminals with the contactor activated The resistance should be very low 0 to 1 ohm If the resistance is high or open between the two large terminals when the contactor is activated the contactor is faulty Replace If the contactor activates and the resistance between the terminals is low when the 12 VDC is applied the contactor is good NOTE When the contactor is not activated 12 the resistance between the terminals should be very high infinite If the resistance is always low the contacts are stuck and the contactor is faulty Replace When the test is complete replace leads 106B 106C and 107A Replace the lead previously removed from one of the contactor large terminals Replace the tool tray Figure F 7 Contactor Terminals and Leads Output Contactor POWER
120. ures 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 Return to Section TOC Return to Master TOC POWER MIG 215 LINCOLN F 9 TROUBLESHOOTING AND REPAIR F 9 Troubleshooting Guide see wiring Diagrams for location of specified Observe Safety Guidelines components and for troubleshooting of specific circuits detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Poor arc striking with electrode 1 Make sure the settings for wire 1 The output capacitors may be faulty sticking or blasting off feed speed and voltage are cor Check for loose connections at the rect for the process being used capacitors Also check for leaky capacitors Replace if necessary Return to Section TOC Return to Master TOC Make certain the gas shielding is correct for the process being WARNING The liquid electrolyte in used these capacitors is toxic Avoid con tact with any portion of your body Make sure the machine s recon nect panel is configured properly 2 Perform the for the input voltage being applied The arc is unstable and or hunting 1 Check for a worn or melted con 1 Check for loose or faulty connections tact tip at the output terminals choke output capacitors output selector switch C
121. ve the gas nozzle and nozzle insulator if used to locate the set screw in the gas diffuser which is used to hold the old liner in place Loosen the set screw with a 5 64 2 0 mm Allen wrench 2 Remove the gas diffuser from the gun tube 3 Lay the gun and cable out straight on a flat surface Loosen the set screw located in the brass connec tor at the feeder end of the cable and pull the liner out of the cable 4 Insert a new untrimmed liner into the connector end of the cable Be sure the liner bushing is stencilled appropriately for the wire size bing used 5 Fully seat the liner bushing into the connector tight en the set screw on the brass cable connector the gas diffuser at this time should not be installed onto the end of the gun tube 6 With the gas diffuser still removed from the gun tube be sure the cable is straight and then trim the liner to the length shown in Figure D 1 Remove any burrs from the end of the liner 045 1 2 mm 3 64 1 2 mm KP2026 3 KP2026 2 KP2026 3 KP2026 2 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 SET SCREW BRASS CABLE CONNECTOR 4 1 4 31 8mm LINER TRIM SET p GAS MM Mer S NOZZLE INSULATO
122. witch the user can preset the desired voltage output CONTACTOR CONTROL CONTACTOR WIRE SPEED CONTROL TRANSFORMER OUTPUT BRIDGE THERMOSTAT THERMOSTAT OUTPUT POSITIVE CHOKE TERMINAL CAPACITORS NEGATIVE TERMINAL from a minimum setting A to a maximum voltage setting G In addition the main transformer also has a 28VAC winding This 28VAC is rectified at the baffle mounted diode bridge The resultant DC voltage approx 35VDC is used to power the electronics on the control board NOTE Unshaded areas of block logic diagrams are the subject of discussion POWER MIG 215 LINCOLN GUN ASSEMBLY O R E 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC OJO c 89 S a g L cle 55 d c Return to Section TOC Return to Master TOC E 3 THEORY OF OPERATION E 3 FIGURE E 3 CONTROL CIRCUITS WIRE GAS SPEED SOLENOID CONTROL CONTROL BOARD RECTIFIER DIODE BRIDGE TRANSFORMER OUTPUT BRIDGE THERMOSTAT THERMOSTAT TAP SELECTOR SWITCH CONTACTOR CONTROL GUN ASSEMBLY OUTPUT POSITIVE CHOKE TERMINAL CONTACTOR OUTPUT CAPACITORS uH RECONNECT PAN MAIN EL TRANSFORMER NEGATIVE TERMINAL OUTPUT RECTIFICATION CONTACTOR AND CONTROL BOARD The AC voltage developed on the secondary winding is applied through the selector switch and output co

Lincoln Electric SVM167-A User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents