Lincoln Electric 11521 service manual Perform the Main Transformer

Page 42

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

F-4

TROUBLESHOOTING AND REPAIR

F-4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

 

 

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

Major physical

or electrical

1. Contact

your

local

Lincoln

1. Contact Lincoln Electric Service

damage is evident.

Electric authorized field service

Department 1-888-935-3877.

 

 

facility.

 

 

 

 

 

 

 

 

 

 

 

The machine is dead--no open

1. Make certain the input power

1. Check the input power switch

circuit voltage and no wire feed

switch (S1) is in the “ON”

(S1). It may be faulty.

when the gun trigger is activated.

position.

 

 

 

 

 

2. Check for broken or missing

The cooling fan is not running.

 

 

 

 

 

 

2. Check the input voltage at the

wires at the reconnect panel.

 

 

 

 

machine. The input voltage

3. Perform the Main Transformer

 

 

must match the rating plate and

 

 

the reconnect panel.

 

 

Test.

 

 

 

 

 

 

 

 

 

 

 

3. Check for blown or missing

 

 

 

 

 

fuses in the input lines.

 

 

 

 

 

 

 

There is no open circuit voltage or

1. Make sure the input voltage is

1. The baffle mounted rectifier

wire feed when the gun trigger is

correct

and

matches

the

bridge may be faulty. Check

activated. The

cooling fan is

nameplate rating and reconnect

and replace if necessary.

running.

 

panel configuration.

 

 

2. Perform the Main Transformer

 

 

 

 

 

 

 

 

 

 

2. One of the two thermostats may

Test.

 

 

 

 

be open due to machine

3. Check the thermostats and

 

 

overheating.

If the machine

 

 

operates

normally

after a

associated leads for loose or

 

 

faulty connections. See the

 

 

cooling off period then check for

 

 

Wiring Diagram.

 

 

 

proper

fan

operation

and

 

 

 

 

 

 

 

 

ventilation.

Make certain the

4. The

internal

triggering

 

 

machine’s

duty cycle is

not

circuit/plugs may be faulty. See

 

 

being exceeded.

 

 

 

 

 

 

the Wiring Diagram.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5. The control board may be faulty.

 

 

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

Power MIG® 215XT

Page 41 Page 43
Image 42
Page 41 Page 43
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 215XTInput POWER, Grounding and Connection Diagrams Safety PrecautionsUncrating the Power MIG 215XT LocationOutput Polarity Connections Shielding GAS GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Cylinder may explode if damagedPower MIG 215XT Table of Contents Operation Section OPERATIONB-2 Wear eye, ear and body protec- tionOperation Procedure for Changing Drive AND IDLE Roll Sets Wire Drive RollWire Size Conversion Parts Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder Feeding Wire ElectrodeWhen triggering, the electrode Changing the Gun Receiver Bushing Electric Shock can killMaking a Weld Return to Return to Section TOCFAN Control Avoiding Wire Feeding ProblemsWire Feed Overload Protection Input Line Voltage VariationsPower MIG 215XT Table of Contents Accessories Section Accessories Magnum 250LX Push Pull Gun K2704-1 Magnum 250LX PUSH-PULL GUN and Push Pull AdapterMake a Weld with the Magnum 250LX PUSH-PULL GUN 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
Top Page Image Contents