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| TROUBLESHOOTING AND REPAIR |
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Troubleshooting Guide – See Wiring Diagrams for location of specified |
| Observe Safety Guidelines | |||||||||
components and for troubleshooting of specific circuits. |
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| detailed in the beginning of this manual. | |||||||
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PROBLEMS |
| POSSIBLE AREAS OF |
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| RECOMMENDED |
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(SYMPTOMS) |
| MISADJUSTMENT(S) |
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| COURSE OF ACTION |
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| OUTPUT PROBLEMS (Continued) |
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Output voltage and wire feed speed | 1. | Remove the gun assembly. | If |
| 1. Check for “shorts” in the trigger | ||||||
is present when the gun trigger is |
| the problem is resolved, the gun |
| circuitry within the | POWER | ||||||
NOT activated. |
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| assembly | is faulty. Repair | or |
| MIG® 215 machine. | See the | |||
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| replace. | If the problem is NOT |
| Wiring Diagram. |
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| resolved, the fault is within the |
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| POWER MIG® 215 machine. |
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| 2. The control board may be faulty. | ||||
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The machines output is low. Welds | 1. | Check the input voltage. Make |
| 1. Check for loose or faulty con- | |||||||
are “cold”. The | weld beads are |
| sure the machine is configured |
| nections on the heavy current | ||||||
rounded or “humped” demonstrat- |
| properly for the input voltage |
| carrying | leads | inside the | |||||
ing poor wetting into the plate. The |
| being applied. |
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| POWER MIG® 215. | See the | |||||
machine cannot obtain full rated |
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| Wiring Diagram. |
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output of 200 amps at 22VDC. | 2. | Make sure the settings for wire |
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| feed speed and voltage are cor- |
| 2. The output capacitors may be | |||||
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| rect for the process being used. |
| faulty. Check for loose connec- | |||||
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| tions at the capacitors. Also | |||
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| 3. Make sure the electrode polarity |
| check for | leaky | capacitors. | ||||
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| is correct for the process being |
| Replace if necessary. |
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| used. |
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| WARNING: The liquid electrolyte | |||
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| 4. Check the welding cables and |
| in these capacitors is toxic. | ||||||
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| gun for loose or faulty connec- |
| Avoid contact with any portion of | |||||
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| tions. |
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| your body. |
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| 3. The output selector switch may | |||
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| be faulty. Check for good con- | |||
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| tact and continuity (zero ohms) | |||
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| through the switch. See the | |||
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| Wiring Diagram. |
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| 4. Perform the Output Contactor | |||
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| Test. |
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| 5. Perform the Output Bridge | |||
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| Rectifier Test. |
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| 6. Perform the Main Transformer | |||
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| Test. |
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The output voltage is continuous | 1. The output contactor may be | 1. Perform the Output Contactor | |||||||||
when the gun trigger is NOT activat- |
| stuck closed. |
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| Test. |
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ed. The wire feed functions normal- |
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ly. |
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call
