Lincoln Electric 11521 service manual Machine Loaded to 180 Amps AT 16 VDC

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F-25	TROUBLESHOOTING AND REPAIR	F-25

ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

(MAX TAP “G”)

ONE OUTPUT DIODE NOT FUNCTIONING

0 volts

20.0 V

5ms

MACHINE LOADED TO 180 AMPS AT 16 VDC

This is NOT a typical DC output volt- age waveform. One output diode is not functioning. Note the increased ripple content. One diode was discon- nected to simulate an open or non- functioning output diode. Each vertical division represents 20 volts and each horizontal division represents 5 mil- liseconds in time. The machine was loaded with a resistance grid bank.

Note: Scope probes connected at machine output terminals: (+) probe to electrode, (-) probe to work.

SCOPE SETTINGS

Volts/Div	20V/Div.
Horizontal Sweep	5 ms/Div.
Coupling	DC
Trigger	Internal

Power MIG® 215XT

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Contents Power MIG 215XT Power MIG 215XT SafetyElectric Shock can kill ARC Rays can burn Welding Cutting For ElectricallyIii 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 These capacitors is toxic Avoid contact with any portionYour 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