Lincoln Electric 11521 service manual PC Board Troubleshooting Procedures

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TROUBLESHOOTING AND REPAIR

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PC BOARD TROUBLESHOOTING PROCEDURES

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WARNING

ELECTRIC SHOCK can kill.

•Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.

CAUTION

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure:

1.Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2.Check for loose connections at the PC board to assure that the PC board is properly connected.

3.If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

-Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shield- ing bag.

-If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.

-If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.

4.Test the machine to determine if the failure symptom has been corrected by the replacement PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5.Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.

a.If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.

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PC board can be damaged by static electricity.

b. If the original problem is recreated by the

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ATTENTION

Static-Sensitive

Devices

Handle only at

Static-Safe

Workstations

-Remove your body’s static charge before opening the static- shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

-If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6.Always indicate that this procedure was followed when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

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-Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.

Power MIG® 215XT

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Contents Power MIG 215XT Power MIG 215XT SafetyElectric Shock can kill ARC Rays can burn Iii Welding CuttingFor Electrically 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 Your body These capacitors is toxicAvoid contact with any portion 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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