E-4

THEORY OF OPERATION

E-4

 

FIGURE E.2 - OPTIONAL CIRCUITS

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LINE

SWITCH

CIRCUIT 115V

BREAKER RECEPTACLE

FAN

MOTOR

 

.8

V

 

 

 

27

AC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPOOL

WIRE

GAS

GUN

SPEED

SOLENOID

SWITCH

CONTROL

 

 

WIRE

 

 

DRIVE

 

 

MOTOR

CONTROL BOARD

 

 

TACH

 

CONTACTOR CONTROL

FEEDBACK

TAP SELECTOR

GUN TRIGGER

 

 

SWITCH

 

 

 

 

OUTPUT DIODE

 

 

BRIDGE

 

 

+

 

 

OUTPUT

 

 

CHOKE

 

CONTACTOR

OUTPUT

 

 

CAPACITORS

-

TRANSFORMER

OUTPUT BRIDGE

THERMOSTAT

THERMOSTAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+

POSITIVE

TERMINAL

-

GUN

ASSEMBLY

Return to

RECONNECT MAIN

PANEL TRANSFORMER

NEGATIVE TERMINAL

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CONTROL BOARD, GUN TRIGGER AND WIRE DRIVE MOTOR

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When the control board receives an activation command from the trigger circuit the control board supplies 12VDC which activates the gas solenoid and output contactor. It also supplies 2 to 29 VDC (depending on the wire speed setting) to the wire drive motor. The control board monitors the motor’s tach feedback signals and compares these to the wire speed control setting. The proper armature voltage is then applied to the wire drive motor. The drive motor speed is thus controlled which in turn regulates the electrode wire feed speed through the gun.

Two self re-setting thermostats are included in the trigger circuitry. If either of these thermostats would “open” due to excessive heat, the trigger circuit would be interrupted and the machine’s output and the wire feed would be disabled. The board also contains overload protection circuitry which protects the drive motor from excessive current draw.

The Power MIG® 215XT is equipped with an adapter panel and switch to allow operation of a spool gun for feeding aluminum wires.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

Power MIG® 215XT

Page 35 Page 37
Page 36
Image 36
Lincoln Electric 11521 service manual Figure E.2 Optional Circuits
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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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