Lincoln Electric 11521 service manual Wire Drive Motor and Tachometer Feedback Test

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TOC

F-17

TROUBLESHOOTING AND REPAIR

F-17

 

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)

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5. Make the following voltage tests:

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•All input power must be electrically disconnected before proceeding.

a.Turn the machine OFF between each test.

b.Carefully insert the meter probes into the lead side of plug J4. See Figure F.4.

c.Turn the machine ON and pull the gun trigger to conduct the voltage test.

FROM LEAD

FROM LEAD

FROM LEAD

Black

White

2-29 VDC

Armature

Armature

(varies depending

Lead

Lead

on wire feed

speed)

 

 

6.If the voltage to the wire drive motor armature is zero, check the wires between plug J4 and the wire drive motor. Also check the electrical con- nector J5 for proper connections and jumper plug. See the Wiring Diagram.

7.If all wires and connectors are good and the volt- age to the drive motor armature is zero, the con- trol PC board may be faulty. Replace the control PC board.

8.If the motor is running at high speed and the armature voltage is high and uncontrollable, Proceed with the tachometer test.

TEST FOR SUPPLY VOLTAGE TO TACHOME- TER

1.Disconnect the main AC input power to the machine.

2.Locate plug J4.

3.Locate the tach leads on plug J4. See Figure

F.5.

4.Connect the main input power to the machine.

5.Make the following voltage tests:

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•All input power must be electrically disconnected before proceeding.

a.Turn the machine OFF between each test.

b.Carefully insert the meter probes into the lead side of plug J4.

FROM LEAD

FROM LEAD

FROM LEAD

Black (-)

Red (+)

5-6 VDC

6.If the 5-6 VDC is present, check the leads to the tachometer circuit.

7.If the leads are okay and 5-6 VDC is present, the correct voltage is being received from the con- trol PC board. Continue with the supply voltage to tachometer test.

8.If the 5-6 VDC is not present and the leads are okay, the control PC board may be faulty, replace the control PC board. Also check plug J5 and the jumper plug. See Wiring Diagram.

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

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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