Lincoln_Electric_Welder

SVM209-A

April, 2011

POWER MIG?? 215XT

For use with machine code number: 11521

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation

. . . and thoughtful operation on your part. DO???NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT READ-

ING THIS MANUAL AND THE

SAFETY PRECAUTIONS CON- TAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL

??? World's Leader in Welding and Cutting Products ???

??? Sales and Service through Subsidiaries and Distributors Worldwide ???

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB???SITE: www.lincolnelectric.com

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WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of ???Safety in Welding & Cutting - ANSI Standard Z49.1??? from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of ???Arc Welding Safety??? booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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1.c. Do not add the fuel near an open flame weld- ing arc or when the engine is running. Stop the engine and allow it to cool before refuel- ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

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1.d. Keep all equipment safety guards, covers and devices in posi- tion and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND

MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Power MIG?? 215XT

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Power MIG?? 215XT

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6.I. Read and follow NFPA 51B ??? Standard for Fire Prevention During Welding, Cutting and Other Hot Work???, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Power MIG?? 215XT

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PR??CAUTIONS DE S??RET??

Pour votre propre protection lire et observer toutes les instructions et les pr??cautions de s??ret?? specifiques qui parraissent dans ce manuel aussi bien que les pr??cautions de s??ret?? g??n??rales suiv- antes:

S??ret?? Pour Soudage A L???Arc

1.Protegez-vous contre la secousse ??lectrique:

a.Les circuits ?? l?????lectrode et ?? la pi??ce sont sous tension quand la machine ?? souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v??tements mouill??s. Porter des gants secs et sans trous pour isoler les mains.

b.Faire tr??s attention de bien s???isoler de la masse quand on soude dans des endroits humides, ou sur un plancher met- allique ou des grilles metalliques, principalement dans

les positions assis ou couch?? pour lesquelles une grande partie du corps peut ??tre en contact avec la masse.

c.Maintenir le porte-??lectrode, la pince de masse, le c??ble de soudage et la machine ?? souder en bon et s??r ??tat defonc- tionnement.

d.Ne jamais plonger le porte-??lectrode dans l???eau pour le refroidir.

e.Ne jamais toucher simultan??ment les parties sous tension des porte-??lectrodes connect??s ?? deux machines ?? souder parce que la tension entre les deux pinces peut ??tre le total de la tension ?? vide des deux machines.

f.Si on utilise la machine ?? souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-??lectrode s???applicuent aussi au pistolet de soudage.

2.Dans le cas de travail au dessus du niveau du sol, se prot??ger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le c??ble-??lectrode autour de n???importe quelle partie du corps.

3.Un coup d???arc peut ??tre plus s??v??re qu???un coup de soliel, donc:

a.Utiliser un bon masque avec un verre filtrant appropri?? ainsi qu???un verre blanc afin de se prot??ger les yeux du rayon- nement de l???arc et des projections quand on soude ou quand on regarde l???arc.

b.Porter des v??tements convenables afin de prot??ger la peau de soudeur et des aides contre le rayonnement de l???arc.

c.Prot??ger l???autre personnel travaillant ?? proximit?? au soudage ?? l???aide d?????crans appropri??s et non-inflammables.

4.Des gouttes de laitier en fusion sont ??mises de l???arc de soudage. Se prot??ger avec des v??tements de protection libres de l???huile, tels que les gants en cuir, chemise ??paisse, pan- talons sans revers, et chaussures montantes.

5.Toujours porter des lunettes de s??curit?? dans la zone de soudage. Utiliser des lunettes avec ??crans lateraux dans les zones o?? l???on pique le laitier.

6.Eloigner les mat??riaux inflammables ou les recouvrir afin de pr??venir tout risque d???incendie d?? aux ??tincelles.

7.Quand on ne soude pas, poser la pince ?? une endroit isol?? de la masse. Un court-circuit accidental peut provoquer un ??chauffement et un risque d???incendie.

8.S???assurer que la masse est connect??e le plus pr??s possible de la zone de travail qu???il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d???autres endroits ??loign??s de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, c??bles de grue, ou autres circuits. Cela peut provoquer des risques d???incendie ou d???echauffement des chaines et des c??bles jusqu????? ce qu???ils se rompent.

9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuli??rement important pour le soudage de t??les galvanis??es plomb??es, ou cadmi??es ou tout autre m??tal qui produit des fume??s toxiques.

10.Ne pas souder en pr??sence de vapeurs de chlore provenant d???op??rations de d??graissage, nettoyage ou pistolage. La chaleur ou les rayons de l???arc peuvent r??agir avec les vapeurs du solvant pour produire du phosg??ne (gas fortement toxique) ou autres produits irritants.

11.Pour obtenir de plus amples renseignements sur la s??ret??, voir le code ???Code for safety in welding and cutting??? CSA Standard W 117.2-1974.

PR??CAUTIONS DE S??RET?? POUR

LES MACHINES ?? SOUDER ??

TRANSFORMATEUR ET ??

REDRESSEUR

1.Relier ?? la terre le chassis du poste conformement au code de l?????lectricit?? et aux recommendations du fabricant. Le dispositif de montage ou la piece ?? souder doit ??tre branch?? ?? une bonne mise ?? la terre.

2.Autant que possible, I???installation et l???entretien du poste seront effectu??s par un ??lectricien qualifi??.

3.Avant de faires des travaux ?? l???interieur de poste, la debranch- er ?? l???interrupteur ?? la boite de fusibles.

4.Garder tous les couvercles et dispositifs de s??ret?? ?? leur place.

Power MIG?? 215XT

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Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer???s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work com- plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equip- ment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic prob- lems in the surrounding area. The following shall be taken into account:

a)other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment;

b)radio and television transmitters and receivers;

c)computer and other control equipment;

d)safety critical equipment, e.g., guarding of industrial equipment;

e)the health of the people around, e.g., the use of pacemakers and hearing aids;

f)equipment used for calibration or measurement

g)the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures;

h)the time of day that welding or other activities are to be carried out.

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Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer???s recommenda- tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equip- ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer???s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equip- ment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer???s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con- nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applica-

tions. 1

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1Portions of the preceding text are contained in EN 60974-10: ???Electromagnetic Compatibility (EMC) prod- uct standard for arc welding equipment.???

Power MIG?? 215XT

I- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

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Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-580

Power MIG?? 215XT

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Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Uncrating the POWER MIG?? 215XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Input Power, Grounding and Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Output Polarity Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Gun and Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Power MIG?? 215XT

NOTE: Use #10 AWG???Grounding Wire

WIRE SPEED RANGE

Wire Speed50 ??? 700 IPM (1.27 ??? 17.8 m/minute)

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

Power MIG?? 215XT

Read entire installation section before starting installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

???Only qualified personnel should perform this installation.

???Only personnel that have read and understood the POWER MIG?? 215XT Operating Manual should install and operate this equipment.

???Machine must be grounded per any national, local or other applicable electrical codes.

???The Power MIG?? power switch is to be in the OFF position when installing work cable and gun and when connecting other equip- ment.

UNCRATING THE POWER MIG?? 215XT

Cut banding and lift off cardboard carton. Cut banding holding the machine to the skid. Remove foam and corrugated packing material. Untape accessories from Gas Bottle Platform. Unscrew the two wood screws (at the Gas Bottle Platform) holding the machine to the skid. Roll the machine off the skid assembly.

LOCATION

Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air pas- sages and cause overheating.

INPUT POWER, GROUNDING AND

CONNECTION DIAGRAMS

WARNING

ELECTRIC SHOCK can kill.

???Do not touch electrically live parts such as output terminals or internal wiring.

???All input power must be electrically dis- connected before proceeding.

1.Before starting the installation, check with the local power company if there is any question about whether your power supply is adequate for the volt- age, amperes, phase, and frequency specified on the welder nameplate. Also be sure the planned installation will meet the U.S. National Electrical Code and local code requirements. This welder may be operated from a single phase line or from one phase of a two or three phase line.

2.Models that have multiple input voltages specified on the nameplate (e.g. 208/230) are shipped con- nected for the highest voltage. If the welder is to be operated on lower voltage, it must be reconnected according to the instructions in Figure A.1 for dual voltage machines.

WARNING

Make certain that the input power is electrically disconnected before removing the screw on the reconnect panel access cover.

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Power MIG?? 215XT

FIGURE A.1 ??? Dual Voltage Machine Input Connections

FIGURE A.2 ??? Receptacle Diagram

Power MIG?? 215XT

GUN AND CABLE INSTALLATION

The Magnum 250L gun and cable provided with the POWER MIG?? 215XT is factory installed with a liner for .035-.045" (0.9-1.2 mm) electrode and an .035" (0.9 mm) contact tip. Be sure that the contact tip, liner, and drive rolls all match the size of the wire being used.

WARNING

Turn the welder power switch off before installing gun and cable.

1.Lay the cable out straight.

2.Unscrew knurled screw on the drive unit front end (inside wire feed compartment) until tip of screw no longer protrudes into gun opening as seen from front of machine.

2.Remove the cylinder cap. Inspect the cylinder valves and regulator for damaged threads, dirt, dust, oil or grease. Remove dust and dirt with a clean cloth.

DO NOT ATTACH THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Inform your gas supplier of this condition. Oil or grease in the presence of high pressure oxygen is explosive.

3.Stand to one side away from the outlet and open the cylinder valve for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet.

WARNING

Be sure to keep your face away from the valve out- let when ???cracking??? the valve.

3.Insert the male end of gun cable into the Gun

Adapter casting through opening in front panel. 4. Attach the flow regulator to the cylinder valve and

Make sure connector is fully inserted and tighten knurled screw.

4.Connect the gun trigger connector from the gun and cable to the mating receptacle inside the compart- ment located above the gun connection made in item 3 above. Make sure that the keyways are aligned, insert and tighten retaining ring.

SHIELDING GAS

(For Gas Metal Arc Welding Processes)

Customer must provide cylinder of appropriate type shielding gas for the process being used.

A gas flow regulator, for Argon blend gas, and an inlet gas hose are factory provided with the POWER MIG?? 215XT. When using 100% CO2 an additional adapter will be required to connect the regulator to the gas bot- tle.

WARNING

CYLINDER may explode if damaged.

??? Gas under pressure is explosive. Always keep gas cylinders in an upright position and always keep chained to undercarriage or stationary support. See American National Standard Z-49.1, ???Safety in Welding and Cutting??? published by the American Welding Society.

Install shielding gas supply as follows:

1.Set gas cylinder on rear platform of POWER MIG?? 215XT. Hook chain in place to secure cylinder to rear of welder.

tighten the union nut(s) securely with a wrench.

NOTE: If connecting to 100% CO2 cylinder, an additional regulator adapter must be installed between the regulator and cylinder valve. If adapter is equipped with a plastic washer, be sure it is seated for connection to the CO2 cylinder.

5.Attach one end of the inlet gas hose to the outlet fit- ting of the flow regulator, the other end to the POWER MIG?? 215XT rear fitting, and tighten the union nuts securely with a wrench.

6.Before opening the cylinder valve, turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released.

7.Standing to one side, open the cylinder valve slow- ly a fraction of a turn. When the cylinder pressure gauge pointer stops moving, open the valve fully.

WARNING

Never stand directly in front of or behind the flow regulator when opening the cylinder valve. Always stand to one side.

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8.The flow regulator is adjustable. Adjust it to the flow rate recommended for the procedure and process being used before making the weld.

AUXILIARY???POWER???RECEPTACLES

(15 Amp 120???Volt Receptacle) The receptacles are UL and CSA???approved.

Power MIG?? 215XT

215XT MIG?? Power

NOTES

6-A

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Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Wire Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5, B-6

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Input Line Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Welding Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Welding Procedure Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Power MIG?? 215XT

B-2

Read entire Operation section before operating the POWER MIG?? 215XT.

WARNING

ELECTRIC SHOCK can kill.

???Do not touch electrically live parts or electrode with skin or wet cloth- ing. Insulate yourself from work and ground.

???Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

??? Keep your head out of fumes.

??? Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

???Keep flammable material away.

???Do not weld on closed containers.

ARC RAYS can burn eyes and skin.

??? Wear eye, ear and body protec- tion.

Observe all safety information throughout this manual.

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Power MIG?? 215XT

PRODUCT DESCRIPTION

The Power MIG?? 215XT is a complete semiautomatic DC voltage arc welding machine built to meet NEMA specifications. It combines a tapped transformer volt- age power source with a constant speed wire feeder to form a reliable robust performance welding system. A simple control scheme, consisting of continuous full range wire feed speed control, and 7 output voltage tap selections provides versatility with ease of use and accuracy. An enhanced feature to the Power MIG?? 215XT, is that it is Magnum 100SG Spool Gun ready.

Other features include a 2" (51 mm) O.D. wire reel spindle with adjustable brake, an integral gas cylinder mounting undercarriage, an adjustable Argon blend flow regulator with cylinder pressure gauge and inlet hose, a 15 ft. (3.6 m) Magnum 250L GMAW gun and cable with fixed (flush) nozzle, a 7 ft. (2.1 m) power cable with plug, and a 10 ft. (3.0 m) work cable with clamp.

Optional Magnum Spool Gun, Push-Pull Guns and Adapter kits, Dual Cylinder Mounting kit and Aluminum Feeding Kit for push feeding with standard built in feed- er are also available.

RECOMMENDED PROCESSES AND

EQUIPMENT

The POWER MIG?? 215XT is recommended for GMA welding processes using 10 to 44 lb (4.5 to 20 kg) 2" (51 mm) I.D. spools or Readi-Reel?? coils (with option- al adapter) of .025" through .045" (0.6 ??? 1.2 mm) solid wire, .035" (0.9 mm) stainless, 3/64" (1.2 mm) alu- minum, .035 (0.9 mm), .045" (1.2 mm) Outershield?? and .045???(1.2mm) Ultracore?? as well as .035" (0.9 mm) and .045" (1.2 mm) Innershield?? self-shielding electrodes.

The Power MIG?? is factory equipped to feed .035" (0.9 mm) electrodes. It also includes a 200A, 60% duty cycle (or 250A, 40% duty cycle) rated, 15 ft. (3.6 m) GMAW gun and cable assembly equipped for these wire sizes. Use of GMAW processes requires a supply of shielding gas.

WELDING CAPABILITY

The POWER MIG?? 215XT is rated at 215 amps @ 22 volts, at a 30% duty cycle based on a ten minute cycle time. It is capable of higher duty cycles at lower output currents. The tapped transformer design makes it well suited for use with most portable or in-plant generating systems.

LIMITATIONS

The output voltage/current of the POWER MIG?? 215XT is subject to vary if the input power to the machine varies, due to its tapped transformer power topology. In some cases an adjustment of WFS preset and/or voltage tap selection may be required to accom- modate a significant drift in input power.

DESCRIPTION OF CONTROLS

See Figure B.1

1.Power ON/OFF Switch ??? Place the lever in the "ON" position to energize the POWER MIG?? 215XT.

2.Voltage Control ??? Seven voltage tap selections are provided Labeled "A" (minimum voltage) through "G" (maximum voltage). It should only be adjusted when not welding. The control selection can be preset to the setting specified on the Procedure Decal on the inside of the wire compart- ment door.

3.Wire Speed Control ??? This controls the wire feed speed from 50 ??? 700 inches per minute (1.2 ??? 17.8 m/min). Wire speed is not affected when changes are made in the voltage control.

FIGURE B.1

4.Magnum Push Gun and spool gun toggle switch-

Toggle the switch to select between push gun and spool gun. When spool gun operation is selected, insert the cable to 4-pin Connector Item 5. (See Figure B.1a)

5.4-Pin Connector-For Spool Gun Operation.

FIGURE B.1a

Power MIG?? 215XT

WIRE DRIVE ROLL

The drive rolls installed with the POWER MIG?? 215XT have two grooves one for .035(0.9mm) wire and the other for .045(1.2mm) wire. Drive roll size is indicated by the stenciling on the exposed side of the drive roll.

WIRE SIZE CONVERSION PARTS

The POWER MIG?? 215XT is rated to feed .025 through .045" (0.6-1.2 mm) solid or cored electrode sizes.

The drive roll kits and Magnum 250L gun and cable parts are available to feed different sizes and types of electrodes. See Accessories section.

1.Open the Wire Drive Compartment Door

2.Depress the Release Bar on the Retaining Collar and remove it from the spindle.

3.Place the Optional Adapter on the spindle

4.Re-install the Retaining Collar. Make sure that the Release Bar ???pops up??? and that the collar retainers fully engage the retaining ring groove on the spindle.

5.Rotate the spindle and adapter so the retaining spring is at the 12 o'clock position.

6.Position the Readi-Reel so that it will rotate in a direction when feeding so as to be de- reeled from top of the coil.

7.Set one of the Readi-Reel inside cage wires on the slot in the retaining spring tab.

8.Lower the Readi-Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter.

9.Slide cage all the way onto the adapter until the retaining spring "pops up" fully.

PROCEDURE FOR CHANGING

DRIVE AND???IDLE ROLL SETS

1.Turn off the power source.

2.Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine. Lift the cast idle roll assembly and allow it to sit in an upright position..

3.Remove the outside wire guide retaining plate by loosening the two large knurled screws.

4.Twist the drive roll retaining mechanism to the unlocked position as shown below and remove the drive rolls. (See Figure B.2)

FIGURE B.2

5.Remove the inside wire guide plate.

6.Replace the drive rolls and inside wire guide with a set marked for the new wire size. NOTE: Be sure that the gun liner and contact tip are also sized to match the selected wire size.

7.Manually feed the wire from the wire reel, over the drive roll groove and through the wire guide and then into the brass bushing of the gun and cable assembly.

8.Replace the outside wire guide retaining plate by tightening the two large knurled screws. Reposition the adjustable pressure arm to its original position to apply pressure. Adjust pressure as necessary.

WIRE REEL LOADING - READI-REELS,

SPOOLS OR COILS

To Mount a 30 Lb. (14 kg) Readi-Reel Package (Using the Molded Plastic K363-P Readi-Reel Adapter:)

CAUTION

CHECK TO BE SURE THE RETAINING SPRING HAS FULLY

RETURNED TO THE LOCKING POSITION AND HAS SECURELY

LOCKED THE READI-REEL CAGE IN PLACE. RETAINING SPRING

MUST REST ON THE CAGE, NOT THE WELDING ELECTRODE.

-----------------------------------------------------------------------------------------------

10.To remove Readi-Reel from Adapter, depress retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove adapter from spindle.

FIGURE B.1

2 IN, O.D. SPINDLE ADAPTER

RETAINING SPRING

BRAKE

HOLDING

To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300 mm Diameter) or 14Lb.(6 Kg) Innershield Coils:

(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil Adapter must be used).

1.Open the Wire Drive Compartment Door

2.Depress the Release Bar on the Retaining Collar and remove it from the spindle.

3.Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the back side of the spool (Note: an arrow mark on the spindle lines up with the brake holding pin to assist in lining up a hole). Be cer- tain the wire comes off the reel in a direction so as to de- reel from the top of the coil.

4.Re-install the Retaining Collar. Make sure that the Release Bar ???pops up??? and that the collar retainers fully engage the retaining ring groove on the spindle.

Power MIG?? 215XT

FEEDING WIRE ELECTRODE

WARNING

When triggering, the electrode and drive mechanism are electrically ???hot??? relative to work and ground and remain ???hot??? several seconds after the gun trigger is released.

------------------------------------------------------------------------

NOTE: Check that drive rolls, guide plates and gun parts are proper for the wire size and type being used. Refer to Table C.1 in Accessories section.

1.Turn the Readi-Reel or spool until the free end of the electrode is accessible.

2.While securely holding the electrode, cut off the bent end and straighten the first six inches. (If the elec- trode is not properly straightened, it may not feed properly through the wire drive system).

3.Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine. Lift the cast idle roll assembly and allow it to sit in an upright position. Leave the outer wire guide plate installed. Manually feed the wire through the incoming guide bushing and through the guide plates (over the drive roll groove). Push a suf- ficient wire length to assure that the wire has fed into the gun and cable assembly without restriction. Reposition the adjustable pressure arm to its origi- nal position to apply pressure to the wire.

4.Press gun trigger to feed the electrode wire through the gun.

IDLE ROLL PRESSURE SETTING

WARNING

ELECTRIC SHOCK can kill.

???Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

???Do not touch electrically live parts.

???When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

???Only qualified personnel should perform mainte- nance work.

------------------------------------------------------------------------

Set the pressure arm as follows (See Figure B.2a):

WIRE DRIVE CONFIGURATION

(See Figure B.2b)

Changing the Gun Receiver Bushing

WARNING

ELECTRIC SHOCK can kill.

???Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides.

???Do not touch electrically live parts.

???When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and could remain energized several seconds after the gun trigger is released.

???Only qualified personnel should perform mainte- nance work.

-----------------------------------------------------------------------

Tools required:

??? 1/4" hex key wrench.

NOTE: Some gun bushings do not require the use of the thumb screw.

1.Turn power off at the welding power source.

2.Remove the welding wire from the wire drive.

3.Remove the thumb screw from the wire drive.

4.Remove the welding gun from the wire drive.

Power MIG?? 215XT

Figure B.2b

5.Loosen the socket head cap screw that holds the connector bar against the gun bushing.

Important: Do not attempt to completely remove the socket head cap screw.

6.Remove the outer wire guide, and push the gun bushing out of the wire drive. Because of the pre- cision fit, light tapping may be required to remove the gun bushing.

7.Disconnect the shielding gas hose from the gun bushing, if required.

8.Connect the shielding gas hose to the new gun bushing, if required.

9.Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate. Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned.

10.Tighten the socket head cap screw.

11.Insert the welding gun into the gun bushing and tighten the thumb screw.

MAKING A WELD

1.Check that the electrode polarity is correct for the process being used, then turn the power switch ON.

2.Set desired arc voltage tap and wire speed for the

particular electrode wire, material type and thick- ness, and gas (for MIG and Outershield??) being used. Use the Application Chart on the door inside the wire compartment as a quick reference for some common welding procedures.

3.Press the trigger to feed the wire electrode through the gun and cable. For solid wire cut the electrode

within approximately 3/8" (10 mm) of the end of the contact tip [3/4" (20 mm) for Outershield??].

4.When welding with gas, turn on the gas supply and set the required flow rate (typically 25-35 CFH; 12- 16 liters/min).

5.Connect work cable to metal to be welded. Work clamp must make good electrical contact to the work. The work must also be grounded as stated in ???Arc Welding Safety Precautions???.

WARNING

???When using an open arc process, it is necessary to use correct eye,

head, and body protection.

-----------------------------------------------------------------------

6.Position electrode over joint. End of electrode may be lightly touching the work.

7.Lower welding helmet, close gun trigger, and begin welding. Hold the gun so the contact tip to work dis-

tance is about 3/8" (10 mm) [3/4" (20 mm) for Outershield??].

8.To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out.

THUMB SCREW

GUN RECEIVER BUSHING

OUTER WIRE GUIDE

CONNECTOR BLOCK

SOCKET HEAD

CAP SCREW

LOOSEN TIGHTEN

Power MIG?? 215XT

9.When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trig- ger to release gas pressure, and turn off POWER MIG?? 215XT.

NOTE: When using Innershield electrode, the gas nozzle may be removed from the insulation on the end of the gun and replaced with the gas- less nozzle. This will give improved visibility and eliminate the possibility of the gas nozzle overheating.

AVOIDING WIRE FEEDING

PROBLEMS

Wire feeding problems can be avoided by observing the following gun handling procedures:

1.Do not kink or pull cable around sharp corners.

2.Keep the gun cable as straight as possible when welding or loading electrode through cable.

3.Do not allow dolly wheels or trucks to run over cables.

4.Keep cable clean by following maintenance instruc- tions.

5.Use only clean, rust-free electrode. The Lincoln electrodes have proper surface lubrication.

6.Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed.

7.Keep wire reel spindle brake tension to minimum required to prevent excess reel over-travel which may cause wire ???loop-offs??? from coil.

8.Use proper drive rolls and wire drive idle roll pres- sure for wire size and type being used.

FAN CONTROL

The fan is designed to come on when input power is applied to the POWER MIG?? 215XT and go off when power is removed.

INPUT LINE VOLTAGE VARIATIONS

High Line Voltage ??? Higher than rated input voltage will result in output voltages higher than normal for a given tap setting. If your input line is high, you may want to select a lower voltage tap than given on the recommended procedure chart.

Low Line Voltage ??? You may not be able to get max- imum output from the machine if the line voltage is less than rated input. The unit will continue to weld, but the output may be less than normal for a given tap setting. If your input line is low, you may want to select a high- er voltage tap than given on the recommended proce- dure chart.

WIRE FEED OVERLOAD

PROTECTION

The POWER MIG?? 215XT 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, and drive rolls, for any obstructions or bends in the gun cable, and 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 pro- tection is done with reliable solid state electronics.

WELDING THERMAL OVERLOAD

PROTECTION

The POWER MIG?? 215XT has built-in protective ther- mostats that respond to excessive temperature. They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating tem- perature because of a frequent overload, or high ambi- ent temperature plus overload. The thermostats auto- matically reset when the temperature reaches a safe operating level and welding and feeding are allowed again, when gun is retriggered.

PROCEDURE CHART

???Contact Tip to Work Distance * Note- Requires Multiple Pass

**.035 & .045 NR-211 MP are only recommended for a maximum steel thickness of 5/16"

Power MIG?? 215XT

215XT MIG?? Power

NOTES

8-B

Return to Master TOC

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Making a Weld with the Spool Gun Adapter Kit and Spool Gun Installed . . . . . . . . . . . . . . . . . . . . . . . . . .C-4

Power MIG?? 215XT

DRIVE ROLL KITS

Refer to Table C.1 for various drive roll kits that are available for the POWER MIG?? 215XT. The item in Bold is supplied standard with the POWER MIG?? 215XT.

TABLE C.1

3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1)

This kit helps push feeding aluminum through standard machine feeder and gun. It provides gun and wire drive conversion parts to weld with 3/64" (1.2 mm) aluminum wire. 5356 alloy aluminum wire is recommended for best push feeding performance.

Kit includes drive rolls and wire guide plate for the wire drive, liner and two contact tips for the gun, along with installation instructions.

READI-REEL ADAPTER (K363P)

The K363P Readi-Reel Adapter mounts to the 2" spin- dle. It is needed to mount the 22-30 lb. Readi-Reels.

DUAL CYLINDER MOUNTING KIT (K1702-1)

ALTERNATIVE MAGNUM GMAW

GUN AND CABLE ASSEMBLIES

The following Magnum 250L gun and cable assemblies are separately available for use with the POWER MIG?? 215XT. Each is rated 250 amps 40% duty cycle and is equipped with the integrated connector, twist- lock trigger connector, fixed nozzle and insulator, and includes a liner, diffuser, and contact tips for the wire sizes specified:

WARNING

???Unplug or Disconnect all input power from the POWER MIG?? 215XT before installing the Spool Gun and Kit.

------------------------------------------------------------------------

MAGNUM GUN CONNECTION KIT

(Optional K466-6)

Using the optional K466-6 Magnum Connection kit for the POWER MIG?? 215XT permits use of standard Magnum 200, 300 or 400 gun and cable assemblies.

OPTIONAL SPOOL GUNS AND

ADAPTERS

The Power MIG?? 215XT is capable of operating with the fol- lowing optional spool guns:

Permits stable side-by-side mounting of two full size 228.6mm dia x 1.524m high(9" dia. x 5' high) gas cylin- ders with ???no lift??? loading. Simple installation and easy instructions provided. Includes upper and lower cylin- der supports, wheel axles and mounting hardware.

SMALL SPOOL SPINDLE ADAPTER (K468)

The K468 spindle adapter allows the use of 8" diame- ter small spools.

Spool gun Adapter (K2703-1)

This kit is designed to allow the Magnum SG or Magnum 250LX spool gun to operate with the Power MIG?? 215XT. The kit includes the solenoid, gas lines, wiring harness and gun connection panel. The gun connection panel features a 6 pin ms-type connector for the Magnum SG spool gun and a 7 pin ms-type connector for the Magnum 250LX spool gun and a selector switch to choose which gun you are using.

Note the K2703-1 spool gun adapter disables the Magnum 100SG capability.

Power MIG?? 215XT

ADAPTER (K2705-1)

FIGURE C.1

4-PIN

CABLE

CONNECTOR

MAGNUM 250LX

PUSH-PULL GUN

7-PIN

CABLE

CONNECTORS

ADAPTER

PLUG INTO

AVAILABLE 120VAC

POWER SOURCE

Power MIG?? 215XT

MAKING A WELD WITH THE SPOOL GUN

ADAPTER KIT AND SPOOL GUN

INSTALLED

CAUTION

In either toggle switch position, closing either gun trigger will cause the electrode of both guns to be electrically ???HOT???. Be sure unused gun is posi- tioned so electrode or tip will not contact metal case or other metal common to work.

-----------------------------------------------------------------------

1.Setting spool gun selector switch to the ???Normal??? position and pulling the trigger for the built-in feed- er gun.

4.Refer to the procedure decal on the Power MIG?? for initial aluminum settings. Make a test weld to determine the final settings.

5.To return to normal POWER MIG?? 215XT welding, release the spool gun trigger set spool gun selector switch to normal and reset feeder gun voltage pro- cedure setting if necessary.

???Disables spool gun operation and spool gun gas solenoid valve.

???Closing feeder gun trigger starts feeder gun welding and makes both electrodes electrically ???HOT???.

2.Setting spool gun selector switch to the Spool Gun Position, select either spool gun and pulling SPOOL GUN Trigger.

???Disables built-in feeder gun operation and machine gas solenoid valve.

???Enables spool gun operation and spool gun gas solenoid valve.

???Closing spool gun trigger starts spool gun weld- ing and makes both electrodes electrically ???HOT???.

3.Operation with POWER MIG?? 215XT:

???Turn the POWER MIG?? 215XT input power ON.

???Adjusting the voltage tap control will increase or decrease your welding voltage.

???Adjusting the wire speed control on the spool gun will increase or decrease the spool gun wire feed speed.

NOTE: Adjusting the wire feed speed control on the Power MIG?? Panel has no affect on the spool gun???s wire feed speed.

Power MIG?? 215XT

Return to Master TOC

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Power MIG?? 215XT

ELECTRIC SHOCK can kill.

??? Have an electrician install and service this equipment.

???Turn the input power off at the fuse box before working on equipment

???Do not touch electrically hot parts.

GENERAL MAINTENANCE

In extremely dusty locations, dirt may clog the air pas- sages causing the welder to run hot. Blow dirt out of the welder with low-pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.

The fan motors have sealed ball bearings which require no service.

???Slip the appropriate gas nozzle onto the nozzle insulator. Either a standard .50" (12.7 mm) or optional .62" (15.9 mm) I.D. slip-on gas nozzle may be used and should be selected based on the welding application.

???Adjust the gas nozzle as appropriate for the GMAW process to be used. Typically, the con- tact tip end should be flush to .12" (3.2 mm) extended for the short-circuiting transfer process and .12" (3.2 mm) recessed for spray transfer.

GUN TUBES AND NOZZLES

1.Replace worn contact tips as required.

2.Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required.

DRIVE ROLLS AND GUIDE PLATES

After every coil of wire, inspect the wire drive mecha- nism. Clean it as necessary by blowing with low pres- sure compressed air. Do not use solvents for cleaning the idle roll because it may wash the lubricant out of the bearing. All drive rolls are stamped with the wire sizes they will feed. If a wire size other than that stamped on the roll is used, the drive roll must be changed.

For instructions on replacing or changing drive roll, see Wire Drive Rolls in Operation section.

CONTACT TIP AND GAS NOZZLE

INSTALLATION

1.Choose the correct size contact tip for the electrode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser.

2.Screw the appropriate fixed gas nozzle fully onto the diffuser. Either the standard .50" (12.7 mm) flush nozzle or other optional flush or recessed (spray arc) nozzle sizes may be used. (See Table D.2 in this section.)

3.If using optional adjustable slip-on nozzles, See Table D.2 in this section.

GUN CABLE CLEANING

To help prevent feeding problems, clean cable liner after using approximately 300 pounds (136 kg) of elec- trode. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using an air hose and only partial pressure, gently blow out the cable liner from the gas diffuser end.

WARNING

Excessive pressure at the beginning of the clean- ing procedure may cause the dirt to form a plug.

-----------------------------------------------------------------------

Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out. If this has been done and feed problems are experienced, try liner replacement, and refer to trouble shooting section on rough wire feeding.

Power MIG?? 215XT

LINER REMOVAL AND REPLACE-

MENT

NOTE: Changing the liner for a different wire size requires replacement of the gas diffuser per Table D.1 to properly secure the different liner.

TABLE D.1

7.Screw the gas diffuser onto the end of the gun tube and securely tighten. Be sure the gas diffuser is cor- rect for the liner being used. (See table and diffuser stencil.)

8.Tighten the set screw in the side of the gas diffuser against the cable liner using a 5/64" (2.0 mm) Allen wrench.

LINER REMOVAL, INSTALLATION AND TRIMMING

INSTRUCTIONS FOR MAGNUM 250L

NOTE: The variation in cable lengths prevents the interchangeability of liners between guns. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Liners are shipped with the jacket of the liner extended the proper amount.

1.Remove the gas nozzle and nozzle insulator, if used, to locate the set screw in the gas diffuser which is used to hold the old liner in place. Loosen the set screw with a 5/64" (2.0 mm) Allen wrench.

2.Remove the gas diffuser from the gun tube.

3.Lay the gun and cable out straight on a flat surface. Loosen the set screw located in the brass connec- tor at the feeder end of the cable and pull the liner out of the cable.

4.Insert a new untrimmed liner into the connector end of the cable. Be sure the liner bushing is stencilled appropriately for the wire size bing used.

5.Fully seat the liner bushing into the connector. tight- en the set screw on the brass cable connector. the gas diffuser, at this time, should not be installed onto the end of the gun tube.

6.With the gas diffuser still removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in Figure D.1. Remove any burrs from the end of the liner.

FIGURE D.1

SET SCREW

BRASS CABLE CONNECTOR

1-1/4" (31.8mm)

LINER

TRIM

LENGTH

SET SCREW

GAS DIFFUSER

NOZZLE INSULATOR (IF USED)

GAS NOZZLE

CAUTION

This screw should only be gently tightened. Overtightening will split or collapse the liner and cause poor wire feeding.

Power MIG?? 215XT

GUN HANDLE DISASSEMBLY

The internal parts of the gun handle may be inspected or serviced if necessary.

The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counterclockwise (the same direction as removing a right hand thread) until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are difficult to turn, position the gun handle against a corner, place a screwdriver against the tab on the collar and give the screwdriver a sharp blow to turn the collar past an internal locking rib.

Counterclockwise

TABLE D.2

ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS

FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES

*Included with POWER MIG?? 215XT

??? Requires KP2026-1 Gas Diffuser Assembly.

Power MIG?? 215XT

FIGURE D.2 - MAJOR COMPONENT LOCATIONS

1.Case Front Assembly

2.Rear Panel Assembly

3.Center Assembly

4.Wire Drive Assembly

5.Base & Power Component Assembly

6.Covers Assembly

Power MIG?? 215XT

215XT MIG?? Power

NOTES

6-D

Return to Master TOC

E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Voltage Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Baffle Mounted Diode Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Output Rectification, Contactor & Control Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Optional Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Control Board, Gun Trigger, & Wire Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Protective Devices & Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

Wirefeed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

FIGURE E.1 BLOCK LOGIC DIAGRAM

Power MIG?? 215XT

INPUT LINE VOLTAGE, MAIN

TRANSFORMER, VOLTAGE

SELECTOR SWITCH AND BAFFLE

MOUNTED DIODE BRIDGE

The single phase input power is connected to the Power MIG?? 215XT through a line switch located on the front panel.

A reconnect panel allows the user to configure the machine for the desired input voltage. The AC input voltage is applied to the primary of the main transformer. The cooling fan motor and 115v receptacle (115VAC) is powered from a portion of the secondary winding. For welding purposes, the main transformer converts the high voltage, low current input power to a low voltage, high current output. This tapped secondary winding is coupled to a voltage selector switch. By selecting one of seven positions on the switch the user can preset the desired voltage output from a minimum setting (A) to a maximum voltage setting (G).

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Power MIG?? 215XT

E-2

GUN

ASSEMBLY

OUTPUT RECTIFICATION, CONTACTOR

AND CONTROL BOARD

The AC voltage developed on the secondary winding is applied, through the selector switch and output contactor, to the output rectifier bridge. This DC welding voltage is filtered by the output capacitors and applied to the output terminals and welding gun. Since the output choke is in series with the positive leg of the output rectifier and also in series with the gun and welding load, a filtered constant voltage output is applied to the output terminals of the machine.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Power MIG?? 215XT

E-3

GUN

ASSEMBLY

FIGURE E.2 - OPTIONAL CIRCUITS

CONTROL BOARD, GUN

TRIGGER AND WIRE DRIVE

MOTOR

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.

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

Power MIG?? 215XT

The Power MIG?? 215XT 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.

The Power MIG?? 215XT 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?? 215XT

215XT MIG?? Power

NOTES

6-E

Return to Master TOC

F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27

Wire Drive Motor Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29

Output Diode Bridge Rectifier Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33

Output Capacitors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37

Main Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41

Fan Blade/Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47

Output Contactor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49

Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-52

WARNING

ELECTRIC SHOCK can kill.

???Never work on the inside of the machine without removing the input power. You can receive a life threatening electrical shock if you fail to do this. Only qualified technicians should perform installation, maintenance, and troubleshooting work on the machine.

Power MIG?? 215XT

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

---------------------------------------------------------------------------------------------------------------------------

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM???(SYMPTOM).

Look under the column labeled ???PROBLEM (SYMPTOMS)???. This column describes pos- sible symptoms that the machine may exhib- it. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into the following categories: output problems, function prob- lems, wire feeding problems, and welding problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled ???POSSIBLE AREAS OF MISADJUSTMENT(S)??? lists the obvious external possibilities that may con- tribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted with- out removing the case wrap-around cover.

Step 3. RECOMMENDED

COURSE OF ACTION

The last column labeled ???Recommended Course of Action??? lists the most likely com- ponents that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject com- ponent is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the specified test points, components, terminal strips, etc. can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

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 1-888-935-3877.

-----------------------------------------------------------------------------------------------------------------------------------

Power MIG?? 215XT

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK can kill.

???Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.

CAUTION

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure:

1.Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2.Check for loose connections at the PC board to assure that the PC board is properly connected.

3.If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

-Remove the PC board from the static-shielding bag and place it directly into the equipment. Don???t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can???t be installed immediately, put it back in the static-shield- ing bag.

-If the PC board uses protective shorting jumpers, don???t remove them until installation is complete.

-If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.

4.Test the machine to determine if the failure symptom has been corrected by the replacement PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5.Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.

a.If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.

PC board can be damaged by static electricity.

b.If the original problem is recreated by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6.Always indicate that this procedure was followed when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, ???INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,??? will help avoid denial of legitimate PC board warranty claims.

-Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.

Power MIG?? 215XT

CAUTION

Power MIG?? 215XT

CAUTION

Power MIG?? 215XT

CAUTION

Power MIG?? 215XT

CAUTION

Power MIG?? 215XT

CAUTION

Power MIG?? 215XT

3.Make sure the electrode polarity is

correct for the welding process 2. Check the output selector switch for

CAUTION

Power MIG?? 215XT

CAUTION

Power MIG?? 215XT

MAIN TRANSFORMER TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if the correct voltages are being applied.

a.Applied to the primary windings of the Main Transformers.

b.Induced on the secondary and auxiliary windings of the Main Transformer.

MATERIALS NEEDED

3/8" wrench 5/16??? Nutdriver Volt-ohmmeter

Power MIG?? 215XT

MAIN TRANSFORMER TEST (continued)

FIGURE F.1 ??? OUTPUT SELECTOR SWITCH TERMINALS

PROCEDURE

WARNING

THE ON/OFF POWER SWITCH will be ???hot??? during these tests.

NOTE: Secondary voltages will vary proportionately with the primary input voltage.

1.Disconnect the main input power supply to the machine.

2.Remove the case top and side panels with a 3/8??? nutdriver.

3.Remove the tool tray with a 5/16??? nut driver.

4.Locate leads X2 thru X8 located on the output selector switch. See Figure F.1.

5.Locate lead X1 located on the output rectifier assembly. See Figure F.2 .

6.Locate leads X9 and X10. See Figure F.3 .

7.Connect main input power to the machine.

8.Turn the Power MIG?????215XT ON/OFF Power Switch to the ON position.

WARNING

ELECTRIC SHOCK can kill.

???Do not touch electrically live parts such as output terminals or inter- nal wiring.

???All input power must be electrical- ly disconnected before proceed- ing.

9.Carefully make the following voltage tests. See Table F.1 .

10.Turn Off the machine.

11.If any of the voltages are incorrect or missing, check for loose or broken connections between the main transformer and the test points.

Power MIG?? 215XT

MAIN TRANSFORMER TEST (continued)

FIGURE F.2 ??? LEAD X1

FIGURE F.3 ??? LEAD X9 & X10

X10

Power MIG?? 215XT

12.If ALL the voltages tested are incorrect or miss- ing, test for correct nameplate input voltage between the H1 lead at the ON/OFF???POWER SWITCH to H2 or H3 at the reconnect panel. Voltage tested will vary depending on input voltage connection. See Wiring Diagram for test point locations.

A.If the input voltage test is incorrect, check for loose or broken leads between the reconnect panel and the ON/OFF POWER SWITCH.

B.Test the ON/OFF???POWER SWITCH for proper operation.

13.If the correct nameplate voltage is being applied to the main transformer and one or more of the secondary voltages are missing or are incorrect, the main transformer may be faulty. Replace.

14.When test is complete, replace tool tray, case sides and top.

Power MIG?? 215XT

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST

WARNING

TEST DESCRIPTION

This test will determine if the Wire Drive Motor and Voltage Feedback Circuit are functioning properly.

MATERIALS NEEDED

5/16??? Nutdriver

Volt-Ohmmeter

Power MIG?? 215XT

PROCEDURE

NOTE: POLARITY MUST BE OBSERVED FOR

THESE TESTS.

Test for correct wire drive motor armature voltage.

1.Disconnect main input power to the machine.

2.Open the side panels and remove the tool tray using a 5/16??? nutdriver.

3.Locate plug J4 on the wiring harness. See Wiring Diagram.

4.Locate the black and white armature leads on plug J4. See Figure F.4.

Power MIG?? 215XT

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)

5. Make the following voltage tests:

WARNING

ELECTRIC SHOCK can kill.

???Do not touch electrically live parts such as output terminals or internal wiring.

???All input power must be electrically disconnected before proceeding.

a.Turn the machine OFF between each test.

b.Carefully insert the meter probes into the lead side of plug J4. See Figure F.4.

c.Turn the machine ON and pull the gun trigger to conduct the voltage test.

6.If the voltage to the wire drive motor armature is zero, check the wires between plug J4 and the wire drive motor. Also check the electrical con- nector J5 for proper connections and jumper plug. See the Wiring Diagram.

7.If all wires and connectors are good and the volt- age to the drive motor armature is zero, the con- trol PC???board may be faulty. Replace the control PC board.

8.If the motor is running at high speed and the armature voltage is high and uncontrollable, Proceed with the tachometer test.

TEST FOR SUPPLY VOLTAGE TO TACHOME-

TER

1.Disconnect the main AC input power to the machine.

2.Locate plug J4.

3.Locate the tach leads on plug J4. See Figure

F.5.

4.Connect the main input power to the machine.

5.Make the following voltage tests:

WARNING

ELECTRIC SHOCK can kill.

???Do not touch electrically live parts such as output terminals or internal wiring.

???All input power must be electrically disconnected before proceeding.

a.Turn the machine OFF between each test.

b.Carefully insert the meter probes into the lead side of plug J4.

6.If the 5-6 VDC is present, check the leads to the tachometer circuit.

7.If the leads are okay and 5-6 VDC is present, the correct voltage is being received from the con- trol PC board. Continue with the supply voltage to tachometer test.

8.If the 5-6 VDC is not present and the leads are okay, the control PC board may be faulty, replace the control PC board. Also check plug J5 and the jumper plug. See Wiring Diagram.

Power MIG?? 215XT

TEST FOR FEEDBACK VOLTAGE TO

CONTROL BOARD

1.Disconnect the main AC input power to the machine.

2.Locate plug J4 and the tach leads. See Figure F.5.

3.Connect main input power to the machine.

4. Make the following voltage tests:

WARNING

ELECTRIC SHOCK can kill.

???Do not touch electrically live parts such as output terminals or internal wiring.

???All input power must be electrically dis- connected before proceeding.

a.Turn the machine OFF between each test.

b.Carefully insert the meter probes into the lead side of plug J4. See Figure F.5.

c.Turn the machine ON and pull the gun trigger to conduct the voltage test.

5.If the 3.0 to 4.0 VDC is present, the tachometer circuit is sending the correct feedback signal to the control PC board. Check the leads and plug J5. See the Wiring Diagram.

6.If the 3.0 to 4.0 VDC is NOT present or NOT correct, the control PC board is not receiving the proper feedback voltage from the tachometer circuit.

7.If the leads are okay, the tachometer circuit may be faulty, replace the tachometer circuit.

8.Replace the tool tray.

Power MIG?? 215XT

OUTPUT BRIDGE RECTIFIER TEST

WARNING

TEST DESCRIPTION

This test will determine if a diode is ???shorted??? or ???leaky???. See the machine waveform section in this manual for normal and abnormal output wave forms.

MATERIALS NEEDED

Analog Volt-ohmmeter or Diode Tester 3/8??? Nutdriver

1/2??? Nutdriver

Power MIG?? 215XT

OUTPUT BRIDGE RECTIFIER TEST (continued)

FIGURE F.6 ??? RECTIFIER TEST POINTS

Negative Lead

PROCEDURE

1.Remove input power to the Power MIG?? 215XT machine.

2.Using the 3/8??? nutdriver, remove the left case side.

3.Locate and disconnect the negative lead from the output rectifier bridge assembly. Be sure there is no electrical contact between the recti- fier and the lead. See Figure F.6.

NOTE: Do not disassemble the rectifier assembly.

4.Test for ???shorted??? or ???leaky??? diodes by checking from the anodes to the cathodes of the diode heatsink plates. The readings should be high resistance in one polarity and low resistance in the opposite polarity.

5.If any of the diodes are ???leaky??? or ???shorted??? the output rectifier assembly should be replaced.

6.When the test is complete, replace the negative output lead previously removed.

7.Replace the left case side.

Power MIG?? 215XT

CONTACTOR TEST

WARNING

TEST DESCRIPTION

This test will determine if the Contactor is functional.

MATERIALS NEEDED

12 VDC Supply

Volt/Ohmmeter

7/16??? Wrench

Power MIG?? 215XT

CONTACTOR TEST (continued)

FIGURE F.7 ??? CONTACTOR TERMINALS AND LEADS

106B

106C

107A

Output

Contactor

PROCEDURE

1.Remove the input power to the Power MIG?? 215XT machine.

2.Using the 5/16??? Nutdriver, remove the tool tray.

3.Locate and remove leads 106B, 106C and 107A from the contactor coil terminals. See Figure F.7. See the Wiring Diagram.

4.Using the 7/16??? wrench, remove one lead from the contactors large terminals. See Figure F.7. See the Wiring Diagram.

5.Carefully apply 12 VDC to the contactor coil leads. (small terminals)

CAUTION

Do not leave the 12 VDC applied to the contac- tor coil for a prolonged period of time (15 sec- onds maximum). Damage to contactor may result.

6.If the contactor does not activate when the 12VDC is applied, the contactor is faulty. Replace.

7.If the contactor activates when the 12VDC is applied, check the resistance between the two large terminals with the contactor activated. The resistance should be very low (0 to 1 ohm).

8.If the resistance is ???high??? or ???open??? between the two large terminals when the contactor is acti- vated, the contactor is faulty. Replace.

9.If the contactor activates and the resistance between the terminals is low when the 12 VDC is applied, the contactor is good

NOTE: When the contactor is not activated, the resistance between the terminals should be very high (infinite). If the resistance is always low, the contacts are ???stuck??? and the contactor is faulty. Replace.

10.When the test is complete, replace leads 106B, 106C and 107A.

11.Replace the lead previously removed from one of the contactor large terminals.

12.Replace the tool tray.

Power MIG?? 215XT

TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

(MAX TAP ???G???)

0 volts

MACHINE LOADED TO 200 AMPS AT 22 VDC

This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 10 volts and that each horizontal division rep- resents 5 milliseconds 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

Power MIG?? 215XT

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP ???G???)

0 volts

This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division rep- resents 1.0 milliseconds in time.

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

SCOPE SETTINGS

Power MIG?? 215XT

ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

(MAX TAP ???G???)

ONE OUTPUT DIODE NOT FUNCTIONING

0 volts

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

Power MIG?? 215XT

ABNORMAL OPEN CIRCUIT VOLTAGE

OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP ???G???)

0 volts

This is NOT a typical DC output volt- age waveform. The output capacitors are not functioning. Note the lack of ???filtering??? in the output waveform. The output capacitor bank was disconnect- ed. Each vertical division represents 20 volts and each horizontal division represents 5 milliseconds in time.

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

SCOPE SETTINGS

Power MIG?? 215XT

CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE

WARNING

TEST DESCRIPTION

The following procedure will aid the technician in removing the Control Board for replacement.

MATERIALS NEEDED

5/16??? Nutdriver

Power MIG?? 215XT

CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.8 ??? CONTROL BOARD MOUNTING PINS

DEPRESS

LOCKING TAB ON

MOUNTING PIN

PROCEDURE

1.Remove power to the machine.

2.Using a 5/16??? nutdriver, remove the three screws securing the tool tray.

3.Locate the control board.

4.Disconnect all associated plugs and leads con- nected to the control board.

5.Depress the retaining pins on the sides of the four nylon mounts to release the control board. See Figure F.8.

6.Carefully remove the control board.

7.Mount the new board to the nylon mounting pins.

8.Reconnect any plugs or leads previously removed.

9.Replace the tool tray previously removed.

Power MIG?? 215XT

WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE

WARNING

TEST DESCRIPTION

The following procedure will aid the technician in removing the Wire Drive and Tachometer for repair or replacement.

MATERIALS NEEDED

5/16??? Nutdriver

9/16??? Nutdriver

Pliers

Small Flathead Screwdriver

Power MIG?? 215XT

WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.9 ??? WIRE DRIVE LOCATION

Wire Drive

PROCEDURE

1.Remove power to the machine.

2.Lift cover to gain access to the wire drive. See Figure F.9.

3.Using a pair of pliers, disconnect the gas hose from the bottom of the wire drive. See Figure

F.10.

4.Using a 9/16??? nut driver, remove the thick black positive lead located just above the gas hose.

See Figure F.10.

NOTE: Disconnect lead from the wire drive motor assembly, not the machine.

5.Using a 5/16??? nutdriver, remove the three mounting screws next to the wire drive assem- bly. See Figure F.10.

6.Using a 5/16??? nutdriver, remove the two screws on the case front assembly. See Figure F.11.

7.Carefully maneuver the wire drive assembly out the side of the machine to gain access to plug J4. See Wiring Diagram.

8.Disconnect plug J4.

Power MIG?? 215XT

WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.10 ??? WIRE DRIVE HOSE & LEAD LOCATION

5/16" Sheet

Metal Screws

9/16" Bolt

Gas Hose

FIGURE F.11 ??? MOUNTING SCREW LOCATIONS

5/16" Monuting Screws

Power MIG?? 215XT

WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)

1.Place the new wire drive assembly into its prop- er position.

2.Connect plug J4.

3.Maneuver assembly back into its original posi- tion.

4.Replace all mounting screws previously removed.

5.Using a 3/4??? nut driver, replace the thick black lead previously removed.

6.Reconnect the gas hose to the wire drive assembly.

7.Close case wrap around cover.

Power MIG?? 215XT

OUTPUT DIODE BRIDGE RECTIFIER

REMOVAL AND REPLACEMENT PROCEDURE

WARNING

TEST DESCRIPTION

The following procedure will aid the technician in removing the Output Diode Bridge Rectifier for repair or replacement.

MATERIALS NEEDED

3/8??? Nutdriver

1/2??? Nutdriver

5/16??? Nutdriver

Power MIG?? 215XT

OUTPUT DIODE BRIDGE RECTIFIER

REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.12 ??? OUTPUT DIODE BRIDGE RECTIFIER LOCATION

OUTPUT DIODE

BRIDGE

RECTIFIER

PROCEDURE

1.Using a 3/8??? nutdriver, remove the left side of the case wraparound cover.

2.Locate the output diode bridge rectifier. See Figure F.12.

3.Using a 1/2??? nutdriver label and remove the four thick black leads connected to the rectifier.

NOTE: Be sure to label lead terminals also. Take note of washer placement upon removal.

4.Label and remove leads 104A and 104B. See Wiring Diagram.

5.Using a 5/16??? nutdriver locate and remove the four bolts mounting the rectifier bracket to the bottom of the machine. These bolts can be accessed easily from the bottom of the machine. See Figure F.13.

6.Carefully manipulate the output diode bridge rectifier and the mounting bracket out of the left side of the machine.

7.Using a 1/2??? nutdriver remove the three bolts mounting the bracket to the rectifier. The recti- fier is now ready for repair or replacement. See

Figure F.13.

8.Mount the new rectifier to the mounting bracket using the three 1/2??? bolts.

9.Carefully manipulate the rectifier and mounting bracket as a one back into the machine to its proper location.

10.Mount the unit to the bottom of the machine using the four 5/16??? mounting bolts previously removed.

11.Reconnect leads 104A and 104B previously removed.

12.Reconnect the four thick black leads previous- ly labeled and removed using a 1/2??? nutdriver.

13.Replace the left side of the case wraparound cover.

Power MIG?? 215XT

OUTPUT DIODE BRIDGE RECTIFIER

REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.13 ??? OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET

5/16" Mounting

Bracket Mounting

Bolts

Power MIG?? 215XT

215XT MIG?? Power

NOTES

36-F

OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE

WARNING

TEST DESCRIPTION

The following procedure will aid the technician in removing the Output Capacitors for repair or replacement.

MATERIALS NEEDED

3/8??? Nutdriver

1/2??? Wrench

Power MIG?? 215XT

OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.14 ??? CAPACITOR BANK LOCATION

LOWER RIGHT

CASE WRAPAROUND

COVER

CAPACITOR BANK

ASSEMBLY

PROCEDURE

1.Using a 3/8??? nutdriver, remove the lower right side case wraparound cover. See Figure F.14.

2.Locate capacitor bank. See Figure F.14.

3.Label and remove the five leads connected to the capacitor bank using a 1/2??? wrench. Note washer position upon removal. See Figure

F.15.

4.Using a 3/8??? nutdriver, remove the three capac- itor bank nuts and lock washers from the three mounting bolts. See Figure F.15.

5.Remove the capacitor bank assembly from the machine.

6.Place the new capacitor bank into its proper location inside the machine.

7.Replace the three 3/8??? nuts and lock washers previously removed.

8.Using a 1/2??? wrench, reconnect the five labeled leads and associated washers previously removed.

9.Replace the lower right side case wraparound cover previously removed.

Power MIG?? 215XT

OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.15 ??? MOUNTING SCREW / BOLT LOCATIONS

Lead Mounting

Bolts

}

3/8" Nuts & Lock washers

(3 places)

{

Power MIG?? 215XT

215XT MIG?? Power

NOTES

40-F

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE

WARNING

TEST DESCRIPTION

The following procedure will aid the technician in removing the Main Transformer for repair or replacement.

MATERIALS NEEDED

3/8??? Nutdriver

7/16??? Nutdriver

1/2??? Nutdriver

5/16??? Nutdriver

Flathead Screwdriver

Power MIG?? 215XT

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.16 ??? MAIN TRANSFORMER LOCATION

Main Transformer

1/2" Mounting

Bolts

PROCEDURE

1.Using a 3/8??? nutdriver, remove both sides of the case wraparound cover.

2.Using a 5/16??? nutdriver, remove the tool tray.

3.Locate the main transformer. See Figure F.16.

4.Label and disconnect leads X9, X10, 104B, & 104C. See Figure F.17.

5.Using a flathead screwdriver, Label and discon- nect lead H1B and other associated lead con- nected to the same terminal. These leads are connected to the ON/OFF switch. See Figure

F.17.

6.Using a 7/16??? nutdriver, Label and disconnect leads X8, X7, X6, X5, X4, X3, & X2 from the switch assembly. Note washer position upon removal. See Figure F.18.

7.Using a 1/2??? nutdriver, label and remove lead X1 from the output diode bridge rectifier.

8.Using a 5/16??? Nutdriver, open the rear access panel. See Figure F.20.

9.Disconnect lead 118 from the rear access panel. See Figure F.21.

10.Feed lead 118 toward the inside of the machine.

11.Cut any necessary cable ties.

12.Remove any necessary wiring harnesses.

13.Disconnect lead 121. See Figure F.19.

14.Using a 1/2??? nutdriver, remove the four main transformer mounting bolts and associated washers. See Figure F.16.

Power MIG?? 215XT

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.17 ??? LEADS X9, X10, 104B, 104C, & H1B

104B

104C

X10

H1B

15.Carefully maneuver the main transformer out the left side of the machine.

NOTE: Two people may be needed to maneuver the main transformer out of the machine.

REPLACEMENT

1.Carefully maneuver the new main transformer back into the machine and onto its mounting studs.

2.Using a 1/2??? nutdriver, mount the main trans- former in its proper position.

3.Reconnect leads 118 and 121 previously removed.

4.Using a 5/16??? nutdriver, close the rear access panel previously opened.

5.Reconnect lead X1 to the output diode bridge rectifier.

6.Reconnect leads X8, X7, X6, X5, X4, X3, & X2 previously removed from the switch assembly.

7.Reconnect lead H1B and the other associated lead connected to the same terminal. These leads are connected to the ON/OFF switch.

8.Replace any necessary cable ties and wiring harnesses.

9.Reconnect leads X9, X10, 104B, & 104C. See Wiring Diagram.

10.Using a 5/16??? nutdriver, replace the tool tray.

11.Using a 3/8??? nutdriver, replace both sides of the case wraparound cover.

Power MIG?? 215XT

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.18 ??? LEADS SWITCH LEADS

FIGURE F.19 ??? LEAD 121 & 118

121

118

Power MIG?? 215XT

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.20 ??? REAR ACCESS PANEL

5/16" Nut

REAR

ACCESS

PANEL

FIGURE F.21 ??? REAR ACCESS PANEL (CLOSE-UP)

Lead 118

Power MIG?? 215XT

215XT MIG?? Power

NOTES

46-F

FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE

WARNING

TEST DESCRIPTION

The following procedure will aid the technician in removing the Fan Blade and Fan Motor for repair or replacement.

MATERIALS NEEDED

3/8??? Nutdriver

5/16??? Nutdriver

11/32??? Open-End Wrench

Flathead Screwdriver

Power MIG?? 215XT

FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.22 ??? FAN MOUNTING BOLTS

REAR

Fan

Blade

Fan

Motor

5/16" Bolts

PROCEDURE

1.Using a 3/8??? nutdriver, remove the lower right side of the case wraparound cover.

2.Perform the Output Capacitors Removal and

Replacement Procedure.

3.Using a 5/16??? nutdriver, remove the four fan mounting screws from the rear of the machine. See Figure F.22.

4.Using an open end 11/32??? wrench, remove the two fan motor mounting nuts and lockwashers. See Figure F.22.

5.Using a flathead screwdriver, loosen the fan blade mounting band. See Figure F.22.

6.Pry the fan blade off of the mounting shaft.

NOTE: If fan blade cracks or breaks upon removal, replace it.

7.Carefully maneuver the fan motor and fan blade out of the right side of the machine.

8.Replace the fan motor and fan blade if neces- sary.

9.Tighten the fan blade mounting band.

10.Carefully maneuver the fan assembly into its original position.

11.Replace the two 11/32??? fan motor mounting nuts and lockwashers.

12.Replace the four 5/16??? fan assembly mounting screws in the rear of the machine.

NOTE: Make sure the fan blade is free to rotate when all of the mounting bolts are replaced.

13.Perform the Output Capacitors Removal and

Replacement Procedure.

14.Replace the lower right case cover.

Power MIG?? 215XT

OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE

WARNING

TEST DESCRIPTION

The following procedure will aid the technician in removing the Output Contactor for repair or replacement.

MATERIALS NEEDED

7/16??? Wrench

5/16??? Nutdriver

Power MIG?? 215XT

OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.23 ??? OUTPUT CONTACTOR LEADS

106B

106C

107A

Output

Contactor

PROCEDURE

1.Using a 5/16??? nutdriver, remove the three screws securing the tool tray.

2.Locate the output contactor. See Figure F.23.

3.Using a 7/16??? wrench, label and remove the two thick black leads at the top of the output con- tactor. Note lead and washer placement for reassembly.

4.Remove lead 107A and note lead placement. See Figure F.23.

5.Remove leads 106B and 106C. See Figure F.23.

6.Using a 7/16??? wrench, remove the three mount- ing bolts from the output contactor. Note wash- er positions for replacement. See Figure F.24.

7.Replace output contactor.

8.Using a 7/16??? wrench, mount the new output contactor in its proper location.

9.Reconnect leads 106B, 106C, & 107A to their proper terminals. See Wiring Diagram.

10.Reconnect the two thick black leads previously removed from the top of the output contactor.

11.Replace the tool tray using a 5/16??? nutdriver.

Power MIG?? 215XT

OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.24 ??? OUTPUT CONTACTOR MOUNTING BOLTS

7/16" Mounting

Bolts

Power MIG?? 215XT

OPEN CIRCUIT VOLTAGE

35 - 40 VDC

WIRE SPEED RANGE

50 - 700 IPM (1.27 - 17.8 m/minute)

Power MIG?? 215XT

Return to Master TOC

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram (L12184-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2 Schematic ??? Complete Machine (L12308-1 PG1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3 Schematic - Complete Machine with Spool Gun (L12308-1 PG2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4

Schematic ??? Control???PC Board * ??? (G4414-2 PG1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5 Schematic ??? Control???PC Board ??? (G4414-2 PG2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6 Schematic ??? Control???PC Board ??? (G4414-2 PG3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7

* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-lay- ered and are therefore considered to be unserviceable. Assembly drawings of these boards are no longer provided.

Power MIG?? 215XT

POWER MIG 215XT (208/220/230V) FOR CODE 11521

RECTIFIER

TRANSFORMER ASSEMBLY

THERMOSTAT THERMOSTAT

1104C 1104B 1104A

CONTROL BOARD

1101A 1

1102A 2

1103A 3

1104A 4

1105A 5

1106A 6

1107A 7

1108A 8

1109A 9

1110A 10

1111A 11

1112A 12

1113A 13

1114A 14

1115A 15

1116A 16

L12184-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

pOWEr???miG?? 215XT