Lincoln Electric 11521 service manual Welding Cutting, For Electrically, Iii

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iii

 

 

 

 

SAFETY

 

 

 

iii

 

 

 

 

 

 

 

 

 

 

WELDING

and

CUTTING

CYLINDER may explode

 

SPARKS can cause fire or

if damaged.

 

 

 

 

explosion.

 

 

7.a. Use only

compressed

gas

cylinders

 

 

 

 

 

 

 

6.a. Remove fire hazards from the welding area.If

containing the correct shielding gas for the

 

process used and

properly

operating

 

this is not possible, cover them to prevent the welding sparks

 

regulators

designed

for

the

gas and

 

from starting a fire. Remember that welding sparks and hot

 

pressure used. All hoses, fittings, etc. should be suitable for

 

materials from welding can easily go through small cracks

 

the application and maintained in good condition.

 

 

and openings to adjacent areas. Avoid welding near hydraulic

 

 

 

 

 

 

 

 

lines. Have a fire extinguisher readily available.

7.b. Always keep cylinders in an upright position securely

 

 

 

 

 

 

6.b. Where compressed gases are to be used at the job site,

chained to an undercarriage or fixed support.

 

 

 

 

 

 

 

special precautions should be used to prevent hazardous

7.c. Cylinders should be located:

 

 

 

 

 

situations. Refer to “Safety in Welding and Cutting” (ANSI

 

 

 

 

 

• Away from areas where they may be struck or subjected to

 

Standard Z49.1)

and the

operating

information for the

 

physical damage.

 

 

 

 

 

equipment being used.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6.c. When not welding, make certain no part of the electrode

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

 

 

 

circuit is touching the work or ground. Accidental contact can

 

 

 

 

 

 

 

 

 

cause overheating and create a fire hazard.

7.d. Never allow the electrode, electrode holder or any other

 

 

 

 

 

 

6.d. Do not heat, cut or weld tanks, drums or containers until the

electrically “hot” parts to touch a cylinder.

 

 

 

 

 

 

 

 

proper steps have been taken to insure that such procedures

7.e. Keep your head and face away from the cylinder valve outlet

 

will not cause flammable or toxic vapors from substances

 

when opening the cylinder valve.

 

 

 

 

inside. They can cause an explosion even though they have

 

 

 

 

 

 

 

 

 

 

been “cleaned”. For information, purchase “Recommended

7.f. Valve protection caps should always be in place and hand

 

Safe Practices for the Preparation for Welding and Cutting of

 

tight except when the cylinder is in use or connected for

 

Containers and

Piping

That

Have

Held Hazardous

 

use.

 

 

 

 

 

Substances”, AWS F4.1 from the American Welding Society

 

 

 

 

 

 

 

 

 

 

 

(see address above).

 

 

 

7.g. Read and follow the instructions on compressed gas

 

 

 

 

 

 

cylinders, associated equipment, and CGA publication P-l,

6.e. Vent hollow castings or containers before heating, cutting or

“Precautions for Safe Handling of Compressed Gases in

 

welding. They may explode.

 

 

 

Cylinders,” available from the Compressed Gas Association

 

 

 

 

 

 

1235 Jefferson Davis Highway, Arlington, VA 22202.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

 

 

 

 

 

 

free protective garments such as leather gloves, heavy shirt,

FOR ELECTRICALLY

 

cuffless trousers, high shoes and a cap over your hair. Wear

 

ear plugs when welding out of position or in confined places.

 

powered equipment.

 

Always wear safety glasses with side shields when in a

 

welding area.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8.a. Turn off input power using the disconnect

6.g. Connect the work cable to the work as close to the welding

switch at the fuse box before working on

 

area as practical. Work cables connected to the building

the equipment.

 

 

 

 

framework or other locations away from the welding area

 

 

 

 

 

 

increase the possibility of the welding current passing through

8.b. Install equipment in accordance with the U.S. National

 

lifting chains, crane cables or other alternate circuits. This can

Electrical Code, all local codes and the manufacturer’s

 

create fire hazards or overheat lifting chains or cables until

recommendations.

 

 

 

 

 

they fail.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8.c. Ground the equipment in accordance with the U.S. National

6.h. Also see item 1.c.

 

 

 

 

Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Power MIG® 215XT

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Contents Power MIG 215XT Safety Power MIG 215XTElectric Shock can kill ARC Rays can burn For Electrically Welding CuttingIii 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 Avoid contact with any portion These capacitors is toxicYour 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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