Lincoln Electric 11521 GUN and Cable Installation, Shielding GAS, Auxiliary Power Receptacles

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INSTALLATION

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GUN AND CABLE INSTALLATION

The Magnum 250L gun and cable provided with the POWER MIG® 215XT 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® 215XT. When using 100% CO2 an additional adapter will be required to connect the regulator to the gas bot- tle.

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® 215XT. Hook chain in place to secure cylinder to rear of welder.

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 cylinder valve. If adapter is equipped with a plastic washer, be sure it is seated for connection 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® 215XT rear fitting, and tighten the union nuts securely with a wrench.

6.Before opening the cylinder valve, turn the regulator adjusting knob counterclockwise until the adjusting 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.

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® 215XT

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Contents Power MIG 215XT Power MIG 215XT SafetyElectric Shock can kill ARC Rays can burn For Electrically Welding CuttingIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Power MIG 215XT InstallationUncrating the Power MIG 215XT Safety PrecautionsInput POWER, Grounding and Connection Diagrams LocationOutput Polarity Connections AUXILIARY POWER RECEPTACLES GUN and Cable InstallationShielding GAS Cylinder may explode if damagedPower MIG 215XT Table of Contents Operation Section Wear eye, ear and body protec- tion OPERATIONB-2Operation Wire Size Conversion Parts Wire Drive RollProcedure for Changing Drive AND IDLE Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsWhen triggering, the electrode Feeding Wire ElectrodeTo Start the Welder Changing the Gun Receiver Bushing Electric Shock can killReturn to Return to Section TOC Making a WeldWire Feed Overload Protection Avoiding Wire Feeding ProblemsFAN Control Input Line Voltage VariationsPower MIG 215XT Table of Contents Accessories Section Accessories Make a Weld with the Magnum 250LX PUSH-PULL GUN Magnum 250LX PUSH-PULL GUN and Push Pull AdapterMagnum 250LX Push Pull Gun K2704-1 Magnum 250LX Push Pull Adapter K2705-1Accessories Table of Contents Maintenance Section Maintenance Table D.1 Liner Removal and REPLACE- MentEnglish Metric Description Size GUN Handle DisassemblyFigure D.2 Major Component Locations Power MIG 215XT 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Figure E.2 Input Power CircuitOutput RECTIFICATION, Contactor Control Board Figure E.2 Optional Circuits Protective Devices and Circuits Power MIG 215XT 1TABLE of Contents Troubleshooting and Repair F-1 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 Tachometer Feedback Test Body Welding ProblemsMake certain the shielding gas is Test Description Main Transformer TestX4 X5 ON/OFF Power Switch will be hot during these testsX10 Main Transformer Test Wire Drive Motor and Tachometer Feedback Test J11 Wire Drive Motor and Tachometer Feedback Test J11 Output Bridge Rectifier Test Negative Lead Contactor Test Contactor Test Machine Loaded to 200 Amps AT 22 VDC Typical Output Voltage Waveform Machine Loaded MAX TAP GNormal Open Circuit Voltage Waveform MAX TAP G Machine Loaded to 180 Amps AT 16 VDC Troubleshooting and Repair Control Board Removal and Replacement Procedure Depress Locking TAB on Mounting PIN Wire Drive Motor Removal and Replacement Procedure Wire Drive Bolt Gas Hose TOC Test Description Output Diode Bridge Rectifier Output Diode Bridge RectifierMounting Bracket Mounting Bolts Rectifier Power MIG 215XT Output Capacitors Removal and Replacement Procedure Lower Right Case Wraparound Cover Capacitor Bank Assembly Lead Mounting Bolts Nuts & Lock washers Places Power MIG 215XT Main Transformer Removal and Replacement Procedure Main Transformer Mounting Bolts Replacement X4 X5 Lead Power MIG 215XT FAN Blade / Motor Removal and Replacement Procedure Rear Output Contactor Removal and Replacement Procedure Output Contactor Mounting Bolts Retest After Repair Table of Contents Diagram Section POWEr miG 215XT Power MIG 215XT 208/220/230V for CodeSchEmaTic cOmplETE machiNE l12308-1 pG1 SchEmaTic cOmplETE machiNE l12308-1 pG2 Psoc 1pF Calibrate

11521 specifications

The Lincoln Electric 11521 is a highly regarded choice among welders and metal fabricators, known for its reliability and efficiency. This portable MIG welder excels in delivering professional-grade results, making it suitable for both beginners and experienced welders. One of the standout features of the Lincoln Electric 11521 is its user-friendly design, which facilitates ease of use and enhances the overall welding experience.

Equipped with a powerful 180 amp output, the Lincoln Electric 11521 is capable of tackling a wide range of welding applications. It operates on a standard 230-volt outlet, allowing users to work on various materials, including mild steel, stainless steel, and aluminum, with thicknesses up to 5/16 inch. This versatility is crucial for those who handle different types of projects, from automotive repairs to home improvement tasks.

The welder employs a spool gun for welding aluminum, ensuring a smooth and efficient feeding of the wire. This technology mitigates the problems commonly associated with feeding aluminum wire through a regular gun, providing a seamless experience. Additionally, the Lincoln Electric 11521 features an adjustable welding speed and voltage, enabling users to fine-tune their settings to match the specific requirements of each project. This adaptability leads to better penetration, bead shape, and overall weld quality.

Another important aspect of the Lincoln Electric 11521 is its durability. Constructed with high-quality materials, this welder is designed for tough jobs and can withstand the wear and tear associated with heavy use. The unit's compact size and lightweight design further enhance its practicality, making it easy to transport between job sites or store when not in use.

Safety is a crucial element in welding, and the Lincoln Electric 11521 does not compromise on this aspect. It features a thermal overload protection system, which prevents damage to the machine by shutting it down in case of overheating. The welder also includes a gas-saving mode that intelligently reduces the gas flow during idle times, maximizing efficiency.

In summary, the Lincoln Electric 11521 is a versatile and reliable MIG welder that caters to a wide range of welding needs. With its powerful output, user-friendly features, advanced technologies, and robust safety mechanisms, it is an excellent investment for professionals and hobbyists alike looking to achieve high-quality welds with ease.
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