Protective Devices and Circuits | Lincoln Electric SVM167-A manual

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E-5

THEORY OF OPERATION

E-5

PROTECTIVE DEVICES AND CIRCUITS

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THERMAL AND OVERLOAD PROTECTION

The POWER MIG® 215 has two built-in protective thermostats that respond to excessive temperatures. One is located on the main transformer. The other thermostat is located on the output rectifier heat sink assembly. They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating temperature. This can be caused by a frequent overload or high ambient temperature.

The thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown is caused by excessive output or duty cycle and the fan is operating normally, the power switch may be left on and the reset should occur within a 15 minute period. If the fan is not turning or the air intake louver are obstructed, then the input power must be removed and the fan problem or air obstruction must be corrected.

WIREFEED OVERLOAD PROTECTION

The POWER MIG® 215 has solid state overload protection of the wire drive motor. If the motor becomes overloaded, the protection circuitry turns off the wire feed speed and gas solenoid. Check for proper size tip liner, drive rolls, and any obstructions or bends in the gun cable. Check for any other factors that would impede the wire feeding. To resume welding, simply pull the trigger. There is no circuit breaker to reset, as the protection is done with reliable solid state electronics.

POWER MIG® 215

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Lincoln Electric SVM167-A Protective Devices and Circuits, Thermal and Overload Protection, Wirefeed Overload Protection

Contents

Safety Depends on You Power MIG California Proposition 65 Warnings Safety Can be dangerous Electric Shock can kill ARC Rays can burn Iii Welding and Cutting Sparks can cause fire or explosionCylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Installation SECTION Table of Contents Technical Specifications Power MIG Installation Location Safety PrecautionsUncrating the Power MIG Installation Output Polarity Connections Cylinder may explode if damaged GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Shielding GAS Power MIG Operation SECTION Wear eye, ear and body protec- tion OPERATIONB-2 Operation To Start the Welder Procedure for Changing Drive AND IDLE Roll SetsWire Reel Loading READI-REELS, Spools or Coils Wire Drive Configuration Feeding Wire ElectrodeIdle Roll Pressure Setting Figure B.2b Making a Weld Input Line Voltage Variations Avoiding Wire Feeding ProblemsWire Feed Overload Protection FAN Control Power MIG Accessories SECTION Accessories Adapter KIT and Spool GUN 3ACCESSORIESC-3Installed Making a Weld with the Spool GUN Power MIG Maintenance SECTION Maintenance Table D.1 Liner Removal and Replace Ment English Metric Description Size GUN Handle Disassembly Figure D.2 Major Component Locations Power MIG Theory of Operation SECTION Line Switch Theory of Operation Figure E.2 Input Power Circuit Figure E.3 Control Circuits Output Rectification Contactor and Control Board Figure E.4 Optional Circuits Control BOARD, GUN Trigger and Wire Drive Motor Thermal and Overload Protection Wirefeed Overload ProtectionProtective Devices and Circuits Power MIG TROUBLESHOOTING AND REPAIR SECTION How To Use Troubleshooting Guide Troubleshooting and Repair PC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor Your body These capacitors is toxicAvoid contact with any portion Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Materials Needed Main Transformer TestTest Description Main Transformer Test Test ProcedureON/OFF Power Switch will be hot during these tests X10 Input Voltage Test Points Table F.1. Test Points Wire Drive Motor and Wire Speed Potentiometer Test White Black VDC Test for Feedback Voltage to Control Board1109 a Power MIG Output Bridge Rectifier Test Output Bridge Rectifier Test Negative Lead Contactor Test Figure F.7. Contactor Terminals and Leads Contactor Test Typical Output Voltage Waveform Machine Loaded MAX TAP G Volts 10.0 Normal Open Circuit Voltage Waveform MAX TAP G Volts 20.0 Machine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Description Control Board Replacement Procedure Control Board Replacement Wire Drive Motor Assembly Replacement Wire Drive Motor Assembly Replacement Wire Drive Bolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Figure F.14. Capacitor Bank Location Output Capacitors Replacement Lead Mounting Bolts Nuts Lock washers 3 places Power MIG Main Transformer Replacement 41TROUBLESHOOTING and Repair F-41 See Figure F.17 Main Transformer Replacement Figure F.17. Leads X9, X10, 104B,104C, & H1B Replacement X2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal Procedure FAN BLADE/MOTOR Replacement Output Contactor Replacement Figure F.24 Output Contactor Replacement Mounting Bolts Retest After Repair Table of Contents Electrical Diagrams Section Electrical Diagrams POWEr miG Power MIG 215 208/220/230V Power MIG 215 208/220/230V for Codes 11099 L12308 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG1 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG2 ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS