Lincoln Electric SVM167-A GUN and Cable Installation, Shielding GAS, Auxiliary Power Receptacles

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A-5

INSTALLATION

A-5

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GUN 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.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 outlet and open the cylinder valve for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet.

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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 connector 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% CO2 an additional adapter will be required to connect the regulator to the gas bottle.

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% CO2 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 CO2 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.

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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.

WARNING

Never stand directly in front of or behind the flow regulator when opening the cylinder valve. Always stand to one side.

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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.

POWER MIG® 215

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Contents Safety Depends on You Power MIGCalifornia Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnIii Welding and Cutting Sparks can cause fire or explosionCylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation SECTION  Table of ContentsTechnical Specifications Power MIG InstallationLocation Safety PrecautionsUncrating the Power MIG InstallationOutput Polarity Connections Cylinder may explode if damaged GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Shielding GASPower MIG Operation SECTION  Wear eye, ear and body protec- tion OPERATIONB-2Operation To Start the Welder Procedure for Changing Drive AND IDLE Roll SetsWire Reel Loading READI-REELS, Spools or Coils Wire Drive Configuration Feeding Wire ElectrodeIdle Roll Pressure Setting Figure B.2b Making a WeldInput Line Voltage Variations Avoiding Wire Feeding ProblemsWire Feed Overload Protection FAN ControlPower MIG Accessories SECTION  Accessories Adapter KIT and Spool GUN 3ACCESSORIESC-3Installed Making a Weld with the Spool GUNPower MIG Maintenance SECTION  Maintenance Table D.1 Liner Removal and Replace MentEnglish Metric Description Size GUN Handle DisassemblyFigure D.2 Major Component Locations Power MIG Theory of Operation SECTION  Line SwitchTheory of Operation Figure E.2 Input Power CircuitFigure E.3 Control Circuits Output Rectification Contactor and Control BoardFigure E.4 Optional Circuits Control BOARD, GUN Trigger and Wire Drive MotorThermal and Overload Protection Wirefeed Overload ProtectionProtective Devices and Circuits Power MIG TROUBLESHOOTING AND REPAIR SECTION  How To Use Troubleshooting Guide Troubleshooting and RepairPC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor Your body These capacitors is toxicAvoid contact with any portion Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Materials Needed Main Transformer TestTest Description Main Transformer Test Test ProcedureON/OFF Power Switch will be hot during these tests X10 Input Voltage Test Points Table F.1. Test PointsWire Drive Motor and Wire Speed Potentiometer Test White BlackVDC Test for Feedback Voltage to Control Board1109 a Power MIG Output Bridge Rectifier Test Output Bridge Rectifier Test Negative LeadContactor Test Figure F.7. Contactor Terminals and Leads Contactor TestTypical Output Voltage Waveform Machine Loaded MAX TAP G Volts 10.0Normal Open Circuit Voltage Waveform MAX TAP G Volts 20.0Machine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Description Control Board ReplacementProcedure Control Board ReplacementWire Drive Motor Assembly Replacement Wire Drive Motor Assembly Replacement Wire DriveBolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Figure F.14. Capacitor Bank Location Output Capacitors ReplacementLead Mounting Bolts Nuts Lock washers 3 places Power MIG Main Transformer Replacement 41TROUBLESHOOTING and Repair F-41See Figure F.17 Main Transformer ReplacementFigure F.17. Leads X9, X10, 104B,104C, & H1B ReplacementX2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal Procedure FAN BLADE/MOTOR ReplacementOutput Contactor Replacement Figure F.24 Output Contactor ReplacementMounting Bolts Retest After Repair Table of Contents Electrical Diagrams Section Electrical DiagramsPOWEr miG Power MIG 215 208/220/230VPower MIG 215 208/220/230V for Codes 11099 L12308 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG1SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG2 ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS
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