Lincoln Electric 11521 service manual SchEmaTic cOmplETE machiNE l12308-1 pG2

Page 94

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G-4

 

ElEcTrical DiaGramS

G-4

SchEmaTic - cOmplETE machiNE - l12308-1 pG2

 

 

 

 

 

 

 

 

 

1-L12308

ENGINEERING CONTROLLED

CHANGE DETAIL: REVISED PAGE 2.

 

 

 

 

MANUFACTURER: No

 

 

 

 

 

 

 

 

 

CONTROLSTHE

THESSTANDARDFEEDMOTORCIRCUIT

 

 

CONTROL

 

 

 

 

PTC

 

 

 

 

 

 

 

 

 

 

 

 

FUNCTIONALITYOF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

THEMACHINE

 

ALSOISUSEDFORALLTHESPOOLGUN

 

 

P.C. BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTORSWHENSELECTEDWITH

 

 

 

(SCHEMATIC G4414)

 

 

 

 

 

11J1

FROMSTANDARD

 

 

 

 

 

 

 

 

 

5J1

 

ADAPTERPANEL.

 

SENSINGFOR7-PIN

 

 

REMOTEWFS

 

 

 

 

GUNTRIGGER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REMOTEWFS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPOOLGUNTO

 

 

FOR7-PIN

 

FOR6-PIN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OPERATE

 

 

 

SPOOLGUN

 

SPOOLGUN

 

12J1

FROM112AFEED

 

 

 

 

 

SPOOL GUN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTORNEGLEAD

 

 

 

 

 

GAS SOLENOID

 

 

 

1J3 2J3

6J2

7J14 8J14 5J14

3J14

4J14 1J14

6J14

16J14

15J14 13J14 11J14 10J14

9J14

12J14

2J14

14J14

3J2

5J2

2J2 1J2

4J2

 

 

 

 

 

 

 

 

 

 

 

 

.05

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LOCATEDON

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CASEBACK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

V=8.7VDCWHENGASISFLOWING

 

 

123A 122A

106E

 

 

 

128

129

 

 

 

126A

125A

127A

119A

 

118A 117A

120C

 

 

SPOOL

 

 

 

 

 

COIL: 21.6OHMS, 12VDCCOIL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GAS SOLENOID -

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TOROID

 

GUN

 

 

 

 

 

 

 

GAS SOLENOID +

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6-PIN

 

2.2VDC@50IN/MIN

 

 

 

 

 

 

K2703-1 SPOOL GUN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20VDC@700IN/MIN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AMPHENOL

 

 

 

 

 

 

ADAPTER PANEL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P.M.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

MOTOR +

 

MAX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTOR -

 

 

 

 

 

 

 

LOCATEDON

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DIVIDERPANEL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C

 

WFS

SPOOL GUN POT

 

MOTOR+SPEEDCONTROL

 

 

 

INWIREDRIVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D

 

100K

POT

 

 

 

 

 

COMPARTMENT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

E

 

 

 

 

 

FROMCONTROLBOARD

 

 

 

S2

(TOSWITCHBETWEEN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

F

 

 

 

 

 

 

+

 

**

 

TOGGLE

SPOOLGUNAND

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TOSTANDARDFEEDMOTOR

3J5

105C

SWITCH

STANDARDGUN)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3PB

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

104G

 

 

 

 

 

16J1- POWERTOSTANDARDGASSOLENOIDANDUSED

6J5

6PB

105D

 

105E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPOOL GUN TRIGGER

 

 

1J5

1PB

116C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CLOSINGGUNTRIGGERMAKESBOTH

 

FORSPOOLGUNDETECT(ATCONTROLBOARD)

5J5

5PB

104F

 

104G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FROMSTANDARDGUNTRIGGER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

THESTANDARDGUNANDTHESPOOL

 

 

4J5

4PB

106D

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NORMALLYCLOSED(SHOWN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GUNSELECTRICALLYHOT!

 

 

+40FROMDIODEDRIDGE

 

2J5

2PB

104E

 

INSPOOLGUNPOSITION)

105F

 

 

 

 

 

 

 

 

 

 

119B

 

 

120B

104H

 

 

 

 

 

4J1- TOCONTROLBOARD(TRIGGER)

 

 

 

 

 

 

 

S3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

THERMOSTAT

 

 

 

 

 

SPOOL GUN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SELECTOR

 

 

 

 

 

 

 

SPOOL GUN

 

 

 

 

7-PIN

 

SPOOL GUN TRIGGER

 

 

 

 

 

ALSO SEE

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PAGE 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRIGGER

 

 

 

 

AMPHENOL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

COMMON

 

 

 

 

F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPOOL GUN

 

E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTOR

 

 

B

MOTOR -

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

COMMON

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C

 

 

MAX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D

 

WFS

 

SPOOL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5K

POT

P.M.

GUN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPOOL GUN POT

MOTOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.7VDC@50IN/MIN

105G

A

MOTOR +

24VDC@700IN/MIN

1 TOROID ON BOTH LEADS

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FOR MAGNUM SG AND MAGNUM 250LX

**SPOOL GUNS OPERATION, REMOVE MAGNUM 100SG ADAPTER PANEL (AND HARNESS / SWITCH) FROM P5 OF MACHINE HARNESS AND PLUG IN K2703-1 SPOOL GUN HARNESS

REFER TO L11543-1 FOR SPOOL GUN

ADAPTER PANEL INSTALLATION

INSTRUCTIONS.

 

 

 

 

CAVITY NUMBERING SEQUENCE

LEAD COLOR CODE:

COMPONENT VALUE UNITS:

 

 

 

 

(COMPONENT SIDE OF P.C. BOARD)

 

 

B-BLACK

CAPACITOR: MFD/VOLTS

 

 

 

 

 

 

 

 

 

 

 

 

G-GREEN

RESISTOR: OHMS/WATTS

 

 

 

1

 

8

 

1

3

 

1

 

O-ORANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

J1,

 

 

J2

 

 

J3

 

 

R-RED

CONNECTOR PIN NUMBERS:

 

 

 

J14

 

16

 

 

 

 

 

 

U-BLUE

 

 

 

9

 

4

6

 

 

 

 

 

 

 

 

 

 

 

2

 

W-WHITE

EX. 12 PIN CONNECTOR

 

 

 

 

(NON-LEAD SIDE OF CONNECTOR)

 

 

 

 

 

 

 

Y-YELLOW

1

2

6

 

 

 

 

 

 

 

 

J4 (TRIGGER,

 

LABELS:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TACHOMETER,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

COMMON

 

 

 

 

 

 

 

 

 

 

 

MOTOR SIDE)

 

 

7

 

12

 

 

 

 

 

1

3

 

1

4

 

 

FRAME GROUND

 

 

 

 

 

PA

 

 

 

 

 

 

 

 

 

LATCH

 

 

 

 

 

 

 

 

 

 

 

EARTH GROUND

VIEW OF CONNECTOR ON PC BOARD

 

 

 

 

 

4

6

 

5

8

 

 

PROPRIETARY &

 

 

 

 

 

 

 

 

 

 

 

 

 

 

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED

CONFIDENTIAL:

 

TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

 

MANUFACTURING TOLERANCE PER E2056

CONTROL: CLEVELAND

SCALE:

EQUIPMENT TYPE:

 

POWER MIG 216

 

 

2

2

UNLESS OTHERWISE SPECIFIED TOLERANCE:

 

 

 

ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)

DRAWN BY:

cstuble

NONE

 

 

 

 

 

PAGE ___ OF ___

ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)

IF PRINTED

SUBJECT:

 

 

MACHINE SCHEMATIC

DOCUMENT

 

DOCUMENT

MATERIAL TOLERANCE ("t") TO AGREE

ENGINEER:

T. SPEAR

@ A2 SIZE

 

 

NUMBER:

 

REVISION:

ON ALL ANGLES IS ± .5 OF A DEGREE

 

 

 

 

 

 

 

 

 

 

 

 

L12308-1

C

WITH PUBLISHED STANDARDS.

 

 

UNITS:

MATERIAL

UF

APPROVAL

4/9/2010

PROJECT

CRM41566

REFERENCE:

DO NOT SCALE THIS DRAWING

APPROVED:

OBS

INCH

DISPOSITION:

DATE:

NUMBER:

L12308

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

pOWEr miG® 215XT

Page 93 Page 95
Image 94
Page 93 Page 95
Contents Power MIG 215XT Safety Power MIG 215XTElectric Shock can kill ARC Rays can burn For Electrically Welding CuttingIii 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 Avoid contact with any portion These capacitors is toxicYour 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
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