Lincoln Electric 11521 service manual Perform the Output Contactor

Page 43

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F-5

TROUBLESHOOTING AND REPAIR

 

 

F-5

 

 

 

 

 

 

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

 

RECOMMENDED

 

 

(SYMPTOMS)

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

(continued from previous page)

3. Check the gun trigger leads.

 

 

 

 

 

 

 

Leads #324 to #325 should have

 

 

 

 

 

 

 

continuity (zero ohms) when the

 

 

 

 

 

 

 

gun trigger is activated. If not,

 

 

 

 

 

 

 

the gun trigger or cable may be

 

 

 

 

 

 

 

faulty. Check or replace.

 

 

 

 

 

 

 

4. Check to make sure the switch

 

 

 

 

 

 

 

on the Magnum 100SG Adapter

 

 

 

 

 

 

 

Panel is in the Magnum Push

 

 

 

 

 

 

 

Gun Position.

 

 

 

 

 

 

 

5. If a spool gum option kit is

 

 

 

 

 

 

 

installed, check to make sure it is

 

 

 

 

 

 

 

set to the “normal” position if

 

 

 

 

 

 

 

using the Power MIG® 215XT

 

 

 

 

 

 

 

built in wire feeder.

 

 

 

 

 

 

 

 

 

 

 

 

When the gun trigger is activated

1. Make sure the gun cable and

1.

Check

the

output

selector

and the wire feeds normally, but

work cables are connected prop-

 

switch for proper operation and

there is no open circuit voltage.

erly and in good condition.

 

good connections.

 

 

 

2. Make sure the output selector

2.

Perform the Output Contactor

 

 

switch is in a good condition posi-

 

Test.

 

 

 

 

 

tion and not between positions.

 

 

 

 

 

 

 

 

3. Perform

the

Output

Bridge

 

 

 

 

Rectifier Test.

 

 

 

 

4. Perform the Main Transformer

 

 

 

 

Test.

 

 

 

 

 

 

5. Check the heavy current carry-

 

 

 

 

ing leads between the output

 

 

 

 

selector switch, output contac-

 

 

 

 

tor, output bridge rectifier, and

 

 

 

 

the output terminals for loose or

 

 

 

 

faulty connections. See Wiring

 

 

 

 

Diagram.

 

 

 

 

 

 

 

 

 

 

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

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Contents Power MIG 215XT Power MIG 215XT SafetyElectric Shock can kill ARC Rays can burn For Electrically Welding CuttingIii 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 InstallationLocation Safety PrecautionsUncrating the Power MIG 215XT Input POWER, Grounding and Connection DiagramsOutput Polarity Connections Cylinder may explode if damaged GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Shielding GASPower MIG 215XT Table of Contents Operation Section Wear eye, ear and body protec- tion OPERATIONB-2Operation Wire Reel Loading READI-REELS, Spools or Coils Wire Drive RollWire Size Conversion Parts Procedure for Changing Drive AND IDLE Roll SetsChanging the Gun Receiver Bushing Electric Shock can kill Feeding Wire ElectrodeWhen triggering, the electrode To Start the WelderReturn to Return to Section TOC Making a WeldInput Line Voltage Variations Avoiding Wire Feeding ProblemsWire Feed Overload Protection FAN ControlPower MIG 215XT Table of Contents Accessories Section Accessories Magnum 250LX Push Pull Adapter K2705-1 Magnum 250LX PUSH-PULL GUN and Push Pull AdapterMake a Weld with the Magnum 250LX PUSH-PULL GUN Magnum 250LX Push Pull Gun K2704-1Accessories 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 Avoid contact with any portion These capacitors is toxicYour 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
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