Lincoln Electric SVM167-A service manual Power MIG 215 208/220/230V for Codes 11099

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G-3	ElEcTrical DiaGramS	G-3
WiriNG DiaGram - cOmplETE machiNE - cODE 11099, 11247 - (l12184)

POWER MIG 215 (208/220/230V) FOR CODES 11099 AND 11247

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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
				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

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

CONTROL BOARD

1101A 1

1102A 2

1103A 3

1104A 4

1105A 5

1106A 6

1107A 7

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PA

4	6	5	8

1110A
X10
27.8V	1106C
1106A	1107A

							X9	1114A
							X9
							X8	G
						H1	X7	F
				L1	L2	H1
				L1	L2		X6	E
							X6	E
H3	H4	H2	L1	L2			X5	D
TO SINGLE PHASE									CONTACTOR
SUPPLY LINE						H2	X4	C	CONTACTOR
230220 V		208V		H1	H4	H2	X3	B
W							X3	B
B							X2	A	TAP SELECTOR
B					H1				SWITCH
	RECONNECT					H3			SWITCH
	RECONNECT					H3
G		PANEL			LINE		X1
G					SWITCH	POWER	X11
					S1	TRANSFORMER	X11
TO GROUND PER						TRANSFORMER	115V
TO GROUND PER							115V
NATIONAL ELECTRICAL							X12
CODE

401			401A
	X11

	FAN
	MOTOR
402	X12
402	402A

C1 AND C2 C1				C2
31,000 MFD
50V		+						+
		+						+

										1103A
										R2
								1109A	1113A
									1113A
										WIRE FEED
										SPEED
		1108A
		1116A							J5	PA
	GAS							1116B	1	1 **
	SOLENOID							1104C	2	2
	SOLENOID	1116B						1105A	3	3
		1116B						1105A	3	3
								1106C	4	4
								1104D	5	5
								1105B	6	6
										JUMPER PLUG
		GUN		J6						INSTALLED FOR
		TRIGGER								NON-SPOOL GUN
SINGLE PHASE										NON-SPOOL GUN
SINGLE PHASE		1	324	1						OPERATION
	BRIDGE	2	325	2	1111A		1 **
RECTIFIER		4		4	1104D		1 **
RECTIFIER		3		3			J4
							2
						R	3	1115A
						U	4	1101A
						B	5	1102A
							6	1112A
						B	7	1112A
						W	8	1105B
15A				B
15A					+
403					+	MOTOR/
403				P.M.		MOTOR/
D		D	T	P.M.		GEARBOX
		D	T		-
		U	A
	115V	U	C
		B	H
				W						TO
				W						WORK
R1	40 OHMS
	50 W

1108A 8

J1

1109A 9

1110A 10

1111A 11

1112A 12

1113A 13

1114A 14

1115A 15

1116A 16

OPTION	1
OPTION	5
	2
	3	J2
	4	J2
	4
FOR SPOOL GUN	6
FOR SPOOL GUN	1	J3
	2

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OUTPUT

CHOKE

R.F. FILTER

E

L12184PRINT

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

Image 91

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