Lincoln Electric SVM167-A service manual Power MIG 215 208/220/230V, POWEr miG

Page 90

Section TOC

Master TOC

G-2

ElEcTrical DiaGramS

G-2

WiriNG DiaGram - cOmplETE machiNE - cODE 11070 - (l11986)

 

 

POWER MIG 215 (208/220/230V)

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CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

1

8

1

3

1

J1

 

J2

 

J3

9

16

4

6

2

 

 

 

 

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE

 

B -

BLACK

W -

WHITE

R -

RED

U -

BLUE

INDICATES CONNECTOR CAVITY No.

**CAVITY

NUMBERING SEQUENCE

(NON-LEAD SIDE OF CONNECTOR)

J4 (TRIGGER,

 

 

TACHOMETER,

 

 

MOTOR SIDE)

1

3

1

4

PA

 

 

 

4

6

5

8

 

 

NOTES:

 

N.A.

WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF

 

IMMEDIATE AND FUTURE APPLICATIONS.

N.B.

THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIVE”. TO CHANGE POLARITY, TURN

 

THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK

 

STUD.

RECTIFIER

TRANSFORMER ASSEMBLY

THERMOSTAT THERMOSTAT

1104C 1104B 1104A

1103A

R2

1109A

1113A

WIRE FEED

SPEED

1108A

CONTROL BOARD

1101A 1

1102A 2

1103A 3

1104A 4

1105A 5

1106A 6

1107A 7

1108A 8

J1

1109A 9

1110A 10

1111A 11

1112A 12

1113A 13

1114A 14

1115A 15

1116A 16

1106A

X9

1114A X10

BAFFLE

 

-

MOUNTED

 

RECTIFIER

 

 

DIODE

 

 

BRIDGE

 

 

 

+

 

 

1106B

H1

X10

 

 

27.8V

1106B

1106C

 

1107A

X9

 

 

X8

G

 

X7

F

 

1116A

 

J5

PA

**

GAS

1116B

1

1

SOLENOID

1104C

2

2

 

1105A

3

3

 

1116B

 

 

1106C

4

4

 

 

1104D

5

5

 

 

1105B

6

6

 

 

 

 

JUMPER PLUG

GUN

J6

 

INSTALLED FOR

TRIGGER

 

NON-SPOOL GUN

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H3 H4 H2 L1 L2

TO SINGLE PHASE

SUPPLY LINE

220

V

208V

230

 

 

W

B

RECONNECT

PANEL

G

TO GROUND PER

NATIONAL ELECTRICAL

CODE

L1 L2

H1 H4

H1

LINE

SWITCH

S1

H2

H3

POWER

TRANSFORMER

X6

E

 

 

X5

D

 

 

X4

C

CONTACTOR

 

 

 

X3

B

 

 

X2

A

TAP SELECTOR

 

SWITCH

 

X1

 

 

 

X11

 

 

 

115V

 

 

 

X12

 

 

 

 

 

401

401A

 

 

X11

 

 

 

FAN

 

 

 

MOTOR

 

 

 

X12

402A

 

 

402

SINGLE PHASE

1

324

1

 

 

 

OPERATION

BRIDGE

2

325

2

1111A

J4

 

RECTIFIER

3

 

3

 

 

 

 

4

 

4

1104D

1 **

 

 

 

 

 

 

2

 

 

 

 

 

 

R

3

1115A

 

 

 

 

 

U

4

1101A

 

 

 

 

 

B

5

1102A

 

 

 

 

 

 

6

1112A

 

 

 

 

 

B

7

 

 

 

 

 

W

8

1105B

15A

 

 

B

 

 

 

 

 

 

 

+

 

 

 

403

 

 

 

MOTOR/

 

 

 

 

P.M.

 

 

CIRCUIT

R

T

GEARBOX

 

 

BREAKER

 

-

 

 

 

 

U

A

 

 

 

 

 

115V

C

 

 

 

 

 

 

B

H

 

 

 

 

 

 

 

 

W

 

 

 

TO

 

 

 

 

 

 

WORK

OPTION

1

 

5

 

 

2

 

 

3

J2

 

4

 

 

FOR SPOOL GUN

6

 

1

J3

 

2

 

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C1 AND C2 C1

 

 

 

C2

 

 

31,000 MFD

 

 

 

 

 

 

 

 

 

50V

 

+

 

 

 

 

+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R1

40 OHMS

 

50 W

OUTPUT

 

CHOKE

A

L11986

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.

pOWEr miG® 215

Page 89 Page 91
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Page 89 Page 91
Contents Power MIG Safety Depends on YouSafety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousWelding and Cutting Sparks can cause fire or explosion Cylinder may explode if damagedIii Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SECTION Installation Technical Specifications Power MIGInstallation Safety PrecautionsUncrating the Power MIG LocationOutput Polarity Connections Shielding GAS GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Cylinder may explode if damagedPower MIG Operation SECTION  OPERATIONB-2 Wear eye, ear and body protec- tionOperation Procedure for Changing Drive AND IDLE Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder Feeding Wire Electrode Idle Roll Pressure SettingWire Drive Configuration Making a Weld Figure B.2bFAN Control Avoiding Wire Feeding ProblemsWire Feed Overload Protection Input Line Voltage VariationsPower MIG Accessories SECTION  Accessories Making a Weld with the Spool GUN 3ACCESSORIESC-3Installed 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 CircuitsWirefeed Overload Protection Protective Devices and CircuitsThermal and Overload Protection 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 These capacitors is toxic Avoid contact with any portionYour body Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Main Transformer Test Test DescriptionMaterials Needed Test Procedure ON/OFF Power Switch will be hot during these testsMain Transformer Test X10 Table F.1. Test Points Input Voltage Test PointsWire Drive Motor and Wire Speed Potentiometer Test Black WhiteTest for Feedback Voltage to Control Board 1109 aVDC 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
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