Lincoln Electric 11521 These capacitors is toxic, Avoid contact with any portion, Your body

Page 44

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F-6

TROUBLESHOOTING AND REPAIR

 

F-6

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

PROBLEMS

 

 

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

 

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

Output voltage and wire feed speed

1.

Remove the gun assembly. If the

1. Check for “shorts” in the trigger

is present when the gun trigger is

 

problem is resolved, the gun

circuitry within the Power MIG®

NOT activated.

 

 

assembly

is faulty.

Repair or

215XT

machine.

See the

 

 

 

replace.

If the problem is NOT

Wiring Diagram.

 

 

 

 

resolved, the fault is within the

 

 

 

 

 

 

Power MIG® 215XT machine.

2. The control board may be faulty.

 

 

 

 

The machines output is low. Welds

1.

Check the input voltage. Make

1. Check for loose or faulty con-

are “cold”. The weld beads are

 

sure the machine is configured

nections on the heavy current

rounded or “humped” demonstrat-

 

properly for the input voltage

carrying leads inside the Power

ing poor wetting into the plate. The

 

being applied.

 

MIG® 215XT. See the Wiring

machine cannot obtain full rated

 

 

 

 

Diagram.

 

output of 200 amps at 22VDC.

2.

Make sure the settings for wire

 

 

 

 

 

 

feed speed and voltage are cor-

2. The output capacitors may be

 

 

 

rect for the process being used.

faulty. Check for loose connec-

 

 

 

 

 

 

tions at the capacitors. Also

 

 

3.

Make sure the electrode polarity

check

for leaky

capacitors.

 

 

 

is correct for the process being

Replace if necessary.

 

 

 

used.

 

 

 

 

 

 

 

 

 

 

 

WARNING: The liquid electrolyte

 

 

4. Check the welding

cables and

in these capacitors is toxic.

 

 

 

gun for loose or faulty connec-

Avoid contact with any portion of

 

 

 

tions.

 

 

your body.

 

 

 

 

 

 

 

 

3. The output selector switch may

 

 

 

 

 

 

be faulty. Check for good con-

 

 

 

 

 

 

tact and continuity (zero ohms)

 

 

 

 

 

 

through the switch. See the

 

 

 

 

 

 

Wiring Diagram.

 

 

 

 

 

 

 

4. Perform the Output Contactor

 

 

 

 

 

 

Test.

 

 

 

 

 

 

 

 

5. Perform the Output Bridge

 

 

 

 

 

 

Rectifier Test.

 

 

 

 

 

 

 

6. Perform the Main Transformer

 

 

 

 

 

 

Test.

 

 

 

 

 

 

The output voltage is continuous

1.

The output contactor may be

1. Perform the Output Contactor

when the gun trigger is NOT acti-

 

stuck closed.

 

Test.

 

 

vated. The wire feed functions nor-

 

 

 

 

 

 

 

mally.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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