Lincoln Electric 11521 service manual Accessories

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C-2

ACCESSORIES

C-2

 

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DRIVE ROLL KITS

Refer to Table C.1 for various drive roll kits that are available for the POWER MIG® 215XT. The item in Bold is supplied standard with the POWER MIG® 215XT.

TABLE C.1

Wire

Size

Drive Roll Kit

 

 

 

 

.023”-.030” (0.6-0.8 mm)

KP1696-030S

Solid

.035” (0.9 mm)

KP1696-035S

.045” (1.2 mm)

KP1696-045S

Steel

.035-.045 (0.9-1.2mm)

KP1696-1

 

 

.040 (1.01)

KP1696-2

 

 

 

 

 

 

Cored

.035” (0.9 mm)

KP1697-035C

.045” (1.2 mm)

KP1697-045C

 

Aluminum

3/64” (1.2 mm)

KP1695-3/64A

3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1)

This kit helps push feeding aluminum through standard machine feeder and gun. It provides gun and wire drive conversion parts to weld with 3/64" (1.2 mm) aluminum wire. 5356 alloy aluminum wire is recommended for best push feeding performance.

Kit includes drive rolls and wire guide plate for the wire drive, liner and two contact tips for the gun, along with installation instructions.

READI-REEL ADAPTER (K363P)

The K363P Readi-Reel Adapter mounts to the 2" spin- dle. It is needed to mount the 22-30 lb. Readi-Reels.

DUAL CYLINDER MOUNTING KIT (K1702-1)

ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES

The following Magnum 250L gun and cable assemblies are separately available for use with the POWER MIG® 215XT. Each is rated 250 amps 40% duty cycle and is equipped with the integrated connector, twist- lock trigger connector, fixed nozzle and insulator, and includes a liner, diffuser, and contact tips for the wire sizes specified:

 

 

English Wire

Metric Wire

Length

Part No.

Size

Size

10' (3.0 m)

K533-1

 

 

12' (3.6 m)

K533-7

.035 – .045"

0.9 – 1.2 mm

15' (4.5 m)

K533-3

 

 

 

 

 

 

WARNING

•Unplug or Disconnect all input power from the POWER MIG® 215XT before installing the Spool Gun and Kit.

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MAGNUM GUN CONNECTION KIT (Optional K466-6)

Using the optional K466-6 Magnum Connection kit for the POWER MIG® 215XT permits use of standard Magnum 200, 300 or 400 gun and cable assemblies.

OPTIONAL SPOOL GUNS AND

ADAPTERS

The Power MIG® 215XT is capable of operating with the fol- lowing optional spool guns:

SPOOL GUN

RATING

ADAPTER

 

 

 

Magnum 100SG

Light Duty

Factory Capable

(K2532-1)

130amp 30% Duty Cycle

No Adapter Required

Magnum SG

Medium Duty

 

(K487-25)

250Amp 60% Duty Cycle

Spool Gun Adapter

Magnum 250LX

Heavy Duty

K2703-1

(K2490-1)

300 Amp 60% Duty Cycle

 

 

 

 

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Permits stable side-by-side mounting of two full size 228.6mm dia x 1.524m high(9" dia. x 5' high) gas cylin- ders with “no lift” loading. Simple installation and easy instructions provided. Includes upper and lower cylin- der supports, wheel axles and mounting hardware.

SMALL SPOOL SPINDLE ADAPTER (K468)

The K468 spindle adapter allows the use of 8" diame- ter small spools.

Spool gun Adapter (K2703-1)

This kit is designed to allow the Magnum SG or Magnum 250LX spool gun to operate with the Power MIG® 215XT. The kit includes the solenoid, gas lines, wiring harness and gun connection panel. The gun connection panel features a 6 pin ms-type connector for the Magnum SG spool gun and a 7 pin ms-type connector for the Magnum 250LX spool gun and a selector switch to choose which gun you are using.

Note the K2703-1 spool gun adapter disables the Magnum 100SG capability.

Power MIG® 215XT

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Contents Power MIG 215XT Safety Power MIG 215XTElectric Shock can kill ARC Rays can burn Welding Cutting For ElectricallyIii Précautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Power MIG 215XTSafety Precautions Uncrating the Power MIG 215XTInput POWER, Grounding and Connection Diagrams LocationOutput Polarity Connections GUN and Cable Installation AUXILIARY POWER RECEPTACLESShielding GAS Cylinder may explode if damagedPower MIG 215XT Table of Contents Operation Section OPERATIONB-2 Wear eye, ear and body protec- tionOperation Wire Drive Roll Wire Size Conversion PartsProcedure for Changing Drive AND IDLE Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsFeeding Wire Electrode When triggering, the electrodeTo Start the Welder Changing the Gun Receiver Bushing Electric Shock can killMaking a Weld Return to Return to Section TOCAvoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage VariationsPower MIG 215XT Table of Contents Accessories Section Accessories Magnum 250LX PUSH-PULL GUN and Push Pull Adapter Make a Weld with the Magnum 250LX PUSH-PULL GUNMagnum 250LX Push Pull Gun K2704-1 Magnum 250LX Push Pull Adapter K2705-1Accessories Table of Contents Maintenance Section Maintenance Liner Removal and REPLACE- Ment Table D.1GUN Handle Disassembly English Metric Description SizeFigure D.2 Major Component Locations Power MIG 215XT 1TABLE of CONTENTS-THEORY of Operation Section E-1 Figure E.2 Input Power Circuit Theory of OperationOutput RECTIFICATION, Contactor Control Board Figure E.2 Optional Circuits Protective Devices and Circuits Power MIG 215XT 1TABLE of Contents Troubleshooting and Repair F-1 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 Tachometer Feedback Test Welding Problems BodyMake certain the shielding gas is Main Transformer Test Test DescriptionON/OFF Power Switch will be hot during these tests X4 X5X10 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 Typical Output Voltage Waveform Machine Loaded MAX TAP G Machine Loaded to 200 Amps AT 22 VDCNormal 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 208/220/230V for Code POWEr miG 215XTSchEmaTic 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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