Lincoln Electric 11521 service manual 1TABLE of CONTENTS-THEORY of Operation Section E-1

Page 33

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E-1TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Voltage Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Baffle Mounted Diode Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Output Rectification, Contactor & Control Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Optional Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Control Board, Gun Trigger, & Wire Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Protective Devices & Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5 Wirefeed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

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FIGURE E.1 BLOCK LOGIC DIAGRAM

 

 

 

 

 

SPOOL

WIRE

 

 

 

 

 

 

GAS

GUN

SPEED

 

 

 

 

 

 

SOLENOID

SWITCH

CONTROL

 

 

 

 

 

 

 

 

WIRE

 

 

 

 

 

 

 

 

DRIVE

 

 

 

 

 

 

 

 

MOTOR

 

 

 

CIRCUIT

115V

 

CONTROL BOARD

 

 

 

BREAKER

RECEPTACLE

 

 

 

 

 

 

FAN

 

 

 

 

 

 

 

 

MOTOR

 

 

 

 

 

 

TRANSFORMER

OUTPUT BRIDGE

 

 

 

 

 

 

TACH

 

 

 

V

 

 

FEEDBACK

THERMOSTAT

THERMOSTAT

 

 

.8

 

CONTACTOR CONTROL

 

 

 

 

 

 

 

 

 

 

LINE

 

27

AC

TAP SELECTOR

GUN TRIGGER

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT DIODE

 

 

 

 

 

 

 

 

BRIDGE

 

 

 

 

 

 

 

 

+

+

 

 

 

 

 

 

 

OUTPUT

POSITIVE

 

 

 

 

 

 

CHOKE

 

 

 

 

 

 

TERMINAL

 

 

 

 

 

 

 

 

 

 

 

 

CONTACTOR

OUTPUT

 

 

 

 

 

 

 

 

CAPACITORS

 

 

RECONNECT

 

 

 

 

 

-

-

 

 

MAIN

 

 

 

 

NEGATIVE

PANEL

TRANSFORMER

 

 

 

 

 

 

 

 

TERMINAL

 

 

 

 

 

 

 

GUN

ASSEMBLY

Power MIG® 215XT

Page 32 Page 34
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Page 32 Page 34
Contents Power MIG 215XT Power MIG 215XT SafetyElectric Shock can kill ARC Rays can burn Welding Cutting For ElectricallyIii 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 These capacitors is toxic Avoid contact with any portionYour 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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