Lincoln Electric SVM167-A service manual Avoiding Wire Feeding Problems, FAN Control

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B-7

OPERATION

B-7

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9.When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off POWER MIG® 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 drive 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.

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 that respond to excessive temperature. They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating tem- perature because of a frequent overload, or high ambi- ent temperature plus overload. The thermostats auto- matically reset when the temperature reaches a safe operating level and welding and feeding are allowed again, when gun is retriggered.

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PROCEDURE CHART

 

 

 

 

 

Wire Feed Speed/Voltage Tap Settings

Wire Dia.

Gas Type

Wire Type

Polarity

18 gage

16 gage14 gage

12 gage10gage

3/16

1/4

5/16

3/8

1/2

Outershield

1" CTWD†

 

 

 

 

 

 

 

 

 

 

 

 

.035

75Ar/25CO2

OS71M

DC+

 

 

 

250/D

300/E

350/F

500/G

*500/G

 

 

.035

100%CO2

OS71M

DC+

 

 

 

 

300/E

350/F

500/G

 

 

 

.045

75Ar/25CO2

OS71M

DC+

 

 

 

 

 

200/E

225/F

250/G

250/G

*250/G

Innershield

5/8" CTWD†

 

 

 

 

 

 

 

 

 

 

 

 

.035

NoneReq’d

NR-211MP

DC-

50/B

70/B

80/B

90/C

100/C

 

 

 

 

 

.045

NoneReq’d

NR-211MP

DC-

 

 

 

50/B

70/C

90/C

110/D

**130/E

 

 

.045

NoneReq’d

NR212

DC-

40/B

50/B

60/B

65/C

70/C

90/C

110/D

*130/E

*150/E

*150/E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

†Contact Tip to Work Distance * Note- Requires Multiple Pass

**.035 & .045 NR-211 MP are only recommended for a maximum steel thickness of 5/16"

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 burnCylinder may explode if damaged Welding and Cutting Sparks can cause fire or explosionIii 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 Wire Reel Loading READI-REELS, Spools or Coils Procedure for Changing Drive AND IDLE Roll SetsTo Start the Welder Idle Roll Pressure Setting Feeding Wire ElectrodeWire Drive Configuration 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 MotorProtective Devices and Circuits Wirefeed Overload ProtectionThermal and Overload Protection 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 Avoid contact with any portion These capacitors is toxicYour body Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Test Description Main Transformer TestMaterials Needed ON/OFF Power Switch will be hot during these tests Test ProcedureMain Transformer Test X10 Input Voltage Test Points Table F.1. Test PointsWire Drive Motor and Wire Speed Potentiometer Test White Black1109 a Test for Feedback Voltage to Control BoardVDC 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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