Lincoln Electric SVM167-A service manual Installation, Technical Specifications Power MIG

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INSTALLATION

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TECHNICAL SPECIFICATIONS – POWER MIG® 215

INPUT – SINGLE PHASE ONLY

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Standard Voltage/Phase/Frequency

208/230/1/50/60 Hz

Duty Cycle 30% 40% 60%

Welding Current Range

30 – 250Amps

Input Current @ 170 Amp Rated Output (With 115V receptacle loaded to 15A)

39/35 Amps

RATED OUTPUT

Amps

215Amps

190Amps

170Amps

OUTPUT

Maximum Open Circuit Voltage

35 Volts

Input Current @ 215 Amp Rated Output (With 115V receptacle loaded to 15A)

45/41 Amps

Volts at Rated Amperes

22Volts

23Volts

24Volts

Welding Voltage Range

13.5-24 Volts

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	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	60	45A	10 (6 mm2)	8 (10 mm2)
230/50/60	60	41A	10 (6 mm2)	8 (10 mm2)

NOTE: Use #10 AWG Grounding Wire

WIRE SPEED RANGE

Wire Speed50 – 700 IPM (1.27 – 17.8 m/minute)

PHYSICAL DIMENSIONS

Height	Width	Depth	Weight
31.79 in	18.88 in	38.78 in	210 Ibs
808 mm	480 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

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Contents Power MIG Safety Depends on YouSafety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousIii Welding and Cutting Sparks can cause fire or explosionCylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SECTION Installation Technical Specifications Power MIGSafety Precautions Uncrating the Power MIGInstallation LocationOutput Polarity Connections GUN and Cable Installation AUXILIARY POWER RECEPTACLESShielding GAS Cylinder may explode if damagedPower MIG Operation SECTION OPERATIONB-2 Wear eye, ear and body protec- tionOperation 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 Making a Weld Figure B.2bAvoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage VariationsPower MIG Accessories SECTION Accessories 3ACCESSORIESC-3 InstalledMaking a Weld with the Spool GUN Adapter KIT and Spool GUNPower MIG Maintenance SECTION Maintenance Liner Removal and Replace Ment Table D.1GUN Handle Disassembly English Metric Description SizeFigure D.2 Major Component Locations Power MIG Line Switch Theory of Operation SECTION Figure E.2 Input Power Circuit Theory of OperationOutput Rectification Contactor and Control Board Figure E.3 Control CircuitsControl BOARD, GUN Trigger and Wire Drive Motor Figure E.4 Optional CircuitsThermal and Overload Protection Wirefeed Overload ProtectionProtective Devices and Circuits Power MIG TROUBLESHOOTING AND REPAIR SECTION Troubleshooting and Repair How To Use Troubleshooting GuidePC 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 Table F.1. Test Points Input Voltage Test PointsWire Drive Motor and Wire Speed Potentiometer Test Black WhiteVDC Test for Feedback Voltage to Control Board1109 a Power MIG Output Bridge Rectifier Test Negative Lead Output Bridge Rectifier TestContactor Test Contactor Test Figure F.7. Contactor Terminals and LeadsVolts 10.0 Typical Output Voltage Waveform Machine Loaded MAX TAP GVolts 20.0 Normal Open Circuit Voltage Waveform MAX TAP GMachine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Control Board Replacement DescriptionControl Board Replacement ProcedureWire Drive Motor Assembly Replacement Wire Drive Wire Drive Motor Assembly ReplacementBolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Output Capacitors Replacement Figure F.14. Capacitor Bank LocationLead Mounting Bolts Nuts Lock washers 3 places Power MIG 41TROUBLESHOOTING and Repair F-41 Main Transformer ReplacementMain Transformer Replacement See Figure F.17Replacement Figure F.17. Leads X9, X10, 104B,104C, & H1BX2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal ProcedureOutput Contactor Replacement Output Contactor Replacement Figure F.24Mounting Bolts Retest After Repair Electrical Diagrams Table of Contents Electrical Diagrams SectionPower MIG 215 208/220/230V POWEr miGPower MIG 215 208/220/230V for Codes 11099 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG1 L12308SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG2 ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS