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Lincoln Electric SVM167-A manual

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Table of contents for the manual

  • Page 1

    PO WER MIG ® 215 SER VICE MANUAL SVM167-A January , 201 1 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- IN[...]

  • Page 2

    POWER MIG® 215 SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _____________________[...]

  • Page 3

    SAFETY ii ii POWER MIG® 215 FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which req[...]

  • Page 4

    CYLINDER may explode if damaged. 7. a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 7.b . Always keep cylinders in an upright posi[...]

  • Page 5

    SAFETY iv iv POWER MIG® 215 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: [...]

  • Page 6

    v v POWER MIG® 215 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . .[...]

  • Page 7

    T ABLE OF CONTENTS - INST ALLA TION SECTION - POWER MIG® 215 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Safety Precautions . . . . . . . . . . . . . . . . . . [...]

  • Page 8

    POWER MIG® 215 A-2 A-2 INST ALLA TION 75°C Copper Wire 75°C Copper Wire Input Ampere in Conduit in Conduit Input V oltage/ Fuse or Breaker Rating On A WG (IEC) Sizes A WG (IEC) Sizes (For lengths (For lengths Frequency (Hz) Size (Super Lag) Nameplate up to 100 ft.) exceeding 100 ft.) 208/50/60 60 45A 10 (6 mm 2 ) 8 (10 mm 2 ) 230/50/60 60 41A 10[...]

  • Page 9

    INST ALLA TION A-3 POWER MIG® 215 A-3 Read entire installation section before starting installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and under- stood the POWER MIG® 215 Operating Manual should install and operate this equipment. • Machin[...]

  • Page 10

    INST ALLA TION A-4 POWER MIG® 215 A-4 3. The 208/230 volt 50/60 Hz model POWER MIG® is shipped with a 7 ft.(2.1m). input cable and plug con- nected to the welder . 4. Using the instructions in Figure A.2, have a qualified electrician connect a receptacle (Customer Supplied) or cable to the input power lines and the system ground per the U.S. Nati[...]

  • Page 11

    INST ALLA TION A-5 POWER MIG® 215 A-5 GUN AND CABLE INST ALLA TION The Magnum 250L gun and cable provided with the POWER MIG® 215 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. T ur[...]

  • Page 12

    NOTES A-6 A-6 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 13

    T ABLE OF CONTENTS - OPERA TION SECTION - POWER MIG® 215 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Safety Precautions ................................................................................................B-2 Product Description .............................[...]

  • Page 14

    OPERA TION B-2 B-2 POWER MIG® 215 Read entire Operation section before operating the POWER MIG® 215. 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 [...]

  • Page 15

    POWER MIG® 215 B-3 B-3 OPERA TION PRODUCT DESCRIPTION The POWER MIG® 215 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 o[...]

  • Page 16

    B-4 B-4 OPERA TION POWER MIG® PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS 1. T urn 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 [...]

  • Page 17

    OPERA TION B-5 B-5 POWER MIG® 215 FEEDING WIRE ELECTRODE 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 plate[...]

  • Page 18

    OPERA TION B-6 B-6 POWER MIG® 215 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 [...]

  • Page 19

    OPERA TION B-7 B-7 POWER MIG® 215 9. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off POWER MIG® 215. 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[...]

  • Page 20

    NOTES B-8 B-8 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 21

    T ABLE OF CONTENTS - ACCESSORIES SECTION - POWER MIG® 215 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 3/64” (1.2mm) Aluminum Feeding Kit (K1703-1) . . . . [...]

  • Page 22

    ACCESSORIES C-2 C-2 POWER MIG® 215 DRIVE ROLL KITS Refer to T able C.1 for various drive roll kits that are available for the POWER MIG® 215.The item in Bold is supplied standard with the POWER MIG® 215. T ABLE 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 [...]

  • Page 23

    ACCESSORIES C-3 C-3 POWER MIG® 215 MAKING A WELD WITH THE SPOOL GUN ADAPTER KIT AND SPOOL GUN INST ALLED 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[...]

  • Page 24

    NOTES C-4 C-4 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 25

    T ABLE OF CONTENTS - MAINTENANCE SECTION - POWER MIG® 215 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 General Maintenance . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 26

    MAINTENANCE D-2 D-2 POWER MIG® 215 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn 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 [...]

  • Page 27

    MAINTENANCE D-3 D-3 POWER MIG® 215 LINER REMOV AL AND REPLACE- MENT NOTE: Changing the liner for a different wire size requires replacement of the gas diffuser per T able D.1 to properly secure the different liner . Fixed Adjustable Nozzle Nozzle Replacement Size Stencilled Gas Diffuser Gas Diffuser Diameter of Liner Part on End of Part No. Part N[...]

  • Page 28

    MAINTENANCE D-4 D-4 POWER MIG® 215 GUN HANDLE DISASSEMBL Y 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. T o open up the handle, turn the collars approximately 60 degrees counterclockwise (the same direction as removing a righ[...]

  • Page 29

    MAINTENANCE D-5 D-5 POWER MIG® 215 6 2 3 4 5 1 1. Case Front Assembly 2. Rear Panel Assembly 3. Center Assembly 4. Wire Drive Assembly 5. Base & Power Component Assembly 6. Covers Assembly FIGURE D.2 – MAJOR COMPONENT LOCA TIONS Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC [...]

  • Page 30

    NOTES D-6 D-6 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 31

    T ABLE OF CONTENTS - THEOR Y OF OPERA TION SECTION - POWER MIG® 215 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 Input Line V oltage . . . . . . . . . . . . . . . . . .[...]

  • Page 32

    THEOR Y OF OPERA TION E-2 E-2 POWER MIG® 215 FIGURE E.2 – INPUT POWER CIRCUIT . INPUT LINE VOL T AGE, MAIN TRANSFORMER, VOL T AGE SELECT OR SWITCH AND BAFFLE MOUNTED DIODE BRIDGE The single phase input power is connected to the POWER MIG® 215 through a line switch located on the front panel. A reconnect panel allows the user to configure the ma[...]

  • Page 33

    THEOR Y OF OPERA TION E-3 E-3 POWER MIG® 215 OUTPUT RECTIFICA TION, CONT ACTOR 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 weldin[...]

  • Page 34

    THEOR Y OF OPERA TION E-4 E-4 POWER MIG® 215 CONTROL BOARD, GUN TRIGGER AND WIRE DRIVE MOT OR 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 mo[...]

  • Page 35

    THEOR Y OF OPERA TION E-5 E-5 POWER MIG® 215 P R O T E C T I V E D E V I C E S A N D C I R C U I T S THERMAL AND OVERLOAD PROTECTION Th e PO WER MI G® 215 ha s tw o bui lt- in pro tec tiv e th erm ost ats tha t res pon d to exc ess ive te mpe rat ure s. On e is loc ate d on the mai n tra nsf orm er . T he o the r th erm ost at is lo cat ed on the[...]

  • Page 36

    NOTES E-6 E-6 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 37

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR SECTION - POWER MIG® 215 T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F How to Use T roubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2 PC Board T roubleshooting Procedures . . . . . . . . . . . . . [...]

  • Page 38

    F-2 TROUBLESHOOTING AND REP AIR F-2 POWER MIG® 215 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. Service and Repair should only be performed by Lincoln E[...]

  • Page 39

    F-3 TROUBLESHOOTING AND REP AIR F-3 POWER MIG® 215 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical con- nections. T o avoid problems when trou- bleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that [...]

  • Page 40

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-4 TROUBLESHOOTING AND REP AIR F-4 POWER MIG® 215 PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION [...]

  • Page 41

    When the gun trigger is activated and the wire feeds normally , but there is no open circuit voltage. OUTPUT PROBLEMS (Continued) TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circ[...]

  • Page 42

    O U TP U T P RO B L E M S ( Co n t in u e d ) Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. The machines output is low . W elds are “cold”. The weld beads are rounded or “humped” demonstrat-[...]

  • Page 43

    TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-7 F-7 POWER MIG® 215 If for any reason you do not understand the test procedures or are unable to perform the tests/repai[...]

  • Page 44

    TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-8 F-8 POWER MIG® 215 If for any reason you do not understand the test procedures or are unable to perform the tests/repai[...]

  • Page 45

    TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-9 F-9 POWER MIG® 215 If for any reason you do not understand the test procedures or are unable to perform the tests/repai[...]

  • Page 46

    TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-10 F-10 POWER MIG® 215 If for any reason you do not understand the test procedures or are unable to perform the tests/rep[...]

  • Page 47

    TROUBLESHOOTING AND REP AIR F-11 F-11 POWER MIG® 215 TEST DESCRIPTION This test will determine if the correct voltages are being applied. a. Applied to the primary windings of the Main T ransformers. b. Induced on the secondary and auxiliary windings of the Main Transformer . MA TERIALS NEEDED 3/8” Nutdriver 5/16” Nutdriver V olt-ohmmeter MAIN[...]

  • Page 48

    TEST PROCEDURE 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[...]

  • Page 49

    F-13 TROUBLESHOOTING AND REP AIR F-13 POWER MIG® 215 MAIN TRANSFORMER TEST (continued) FIGURE F .2. – LEAD X1 FIGURE F .3. – LEAD X9 & X10 X1 X9 X10 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 50

    TROUBLESHOOTING AND REP AIR F-14 F-14 POWER MIG® 215 INPUT VOL T AGE TEST POINTS EXPECTED VOL T AGE READING 1 1.9-13.0 V AC 14.1-15.2 V AC 16.2-17.5 V AC 18.4-19.7 V AC 20.5-22.0 V AC 22.7-24.2 V AC 24.8-26.5 V AC 26.9-28.8 V AC X1-X2 X1-X3 X1-X4 X1-X5 X1-X6 X1-X7 X1-X8 X9-X10 230 V AC 230 V AC 230 V AC 230 V AC 230 V AC 230 V AC 230 V AC 230 V AC[...]

  • Page 51

    TROUBLESHOOTING AND REP AIR F-15 F-15 POWER MIG® 215 WIRE DRIVE MOT OR AND WIRE SPEED POTENTIOMETER TEST W ARNING 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 or machine operator and will invalidate your factory war[...]

  • Page 52

    TROUBLESHOOTING AND REP AIR F-16 F-16 POWER MIG® 215 WIRE DRIVE MOT OR AND WIRE SPEED POTENTIOMETER TEST (continued) 1. Make the following voltage tests: 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 volt[...]

  • Page 53

    TROUBLESHOOTING AND REP AIR F-17 F-17 POWER MIG® 215 WIRE DRIVE MOT OR AND WIRE SPEED POTENTIOMETER TEST (continued) TEST FOR FEEDBACK VOL T AGE TO CONTROL BOARD 1. Disconnect the main AC input power to the machine. 2. Locate plug J1 and the potentiometer leads. See Figure F .5. #1 1 13A and 1 109A. 3. Connect main input power to the machine. 4. M[...]

  • Page 54

    NOTES F-18 F-18 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 55

    TROUBLESHOOTING AND REP AIR F-19 F-19 POWER MIG® 215 OUTPUT BRIDGE RECTIFIER TEST 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 or machine operator and will invalidate your factory warranty . For your safety and to a[...]

  • Page 56

    TROUBLESHOOTING AND REP AIR F-20 F-20 POWER MIG® 215 OUTPUT BRIDGE RECTIFIER TEST (continued) TEST PROCEDURE 1. Remove input power to the POWER MIG® 215 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 b[...]

  • Page 57

    TROUBLESHOOTING AND REP AIR F-21 F-21 POWER MIG® 215 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 or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock please [...]

  • Page 58

    TROUBLESHOOTING AND REP AIR F-22 F-22 POWER MIG® 215 107A 106C 106B Output Contactor Figure F .7. Contactor T erminals and Leads CONT ACTOR TEST (Continued) TEST PROCEDURE 1. Remove the input power to the POWER MIG® 215 machine. 2. Using the 5/16” Nutdriver , remove the tool tray . 3. Locate and remove leads 106B, 106C and 107A from the contact[...]

  • Page 59

    TROUBLESHOOTING AND REP AIR F-23 F-23 POWER MIG® 215 TYPICAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED (MAX T AP “G”) 10.0 V 5 ms 0 V olts This is a typical DC output voltage wave- form generated from a properly operat- ing machine. Note that each vertical division represents 10 volts and that each horizontal division represents 5 milliseco[...]

  • Page 60

    TROUBLESHOOTING AND REP AIR F-24 F-24 POWER MIG® 215 NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM (MAX T AP “G”) 20.0 V 1.0 ms 0 V olts This is a typical DC output voltage wave- form generated from a properly operat- ing machine. Note that each vertical division represents 20 volts and that each horizontal division represents 1.0 milliseconds in t[...]

  • Page 61

    TROUBLESHOOTING AND REP AIR F-25 F-25 POWER MIG® 215 ABNORMAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED (MAX T AP “G”) ONE OUTPUT DIODE NOT FUNCTIONING 20.0 V 5 ms 0 V olts This is NOT a typical DC output voltage waveform. One output diode is not func- tioning. Note the increased ripple con- tent. One diode was disconnected to simulate an o[...]

  • Page 62

    TROUBLESHOOTING AND REP AIR F-26 F-26 POWER MIG® 215 ABNORMAL OPEN CIRCUIT VOL T AGE OUTPUT CAP ACITOR BANK NOT FUNCTIONING (MAX T AP “G”) 20.0 V 5 ms 0 V olts This is NOT a typical DC output voltage waveform. The output capacitors are not functioning. Note the lack of “filter- ing” in the output waveform. The output capacitor bank was dis[...]

  • Page 63

    TROUBLESHOOTING AND REP AIR F-27 F-27 POWER MIG® 215 CONTROL BOARD REPLACEMENT 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 or machine operator and will invalidate your factory warranty . For your safety and to avoi[...]

  • Page 64

    TROUBLESHOOTING AND REP AIR F-28 F-28 POWER MIG® 215 CONTROL BOARD REPLACEMENT (continued) 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 connected to the control board. 5. Depress the retaining pins [...]

  • Page 65

    F-29 TROUBLESHOOTING AND REP AIR F-29 POWER MIG® 215 WIRE DRIVE MOT OR ASSEMBL Y REPLACEMENT 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 or machine operator and will invalidate your factory warranty . For your safe[...]

  • Page 66

    F-30 TROUBLESHOOTING AND REP AIR F-30 POWER MIG® 215 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 abo[...]

  • Page 67

    F-31 TROUBLESHOOTING AND REP AIR F-31 POWER MIG® 215 WIRE DRIVE MOT OR ASSEMBL Y REPLACEMENT (Continued) FIGURE F .10. - WIRE DRIVE HOSE & LEAD LOCA TION FIGURE F .1 1. - MOUNTING SCREW LOCA TIONS Gas Hose 9/16" Bolt 5/16" Sheet Metal Screws 5/16" Monuting Screws Return to Section T OC Return to Section T OC Return to Section T [...]

  • Page 68

    TROUBLESHOOTING AND REP AIR F-32 F-32 POWER MIG® 215 1. Place the new wire drive assembly into its proper position. 2. Connect plug J4. 3. Maneuver assembly back into its original position. 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[...]

  • Page 69

    F-33 TROUBLESHOOTING AND REP AIR F-33 POWER MIG® 215 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT 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 or machine operator and will invalidate your factory warranty . For your sa[...]

  • Page 70

    F-34 TROUBLESHOOTING AND REP AIR F-34 POWER MIG® 215 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) 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 t[...]

  • Page 71

    F-35 TROUBLESHOOTING AND REP AIR F-35 POWER MIG® 215 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) 5/16" Mounting Bracket Mounting Bolts 1/2" Rectifier Mounting Bolts Mounting Bracket FIGURE F .13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET Return to Section T OC Return to Section T OC Return to Section T OC Return to Secti[...]

  • Page 72

    F-36 NOTES F-36 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 73

    F-37 TROUBLESHOOTING AND REP AIR F-37 POWER MIG® 215 OUTPUT CAP ACITORS REPLACEMENT 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 or machine operator and will invalidate your factory warranty . For your safety and to[...]

  • Page 74

    F-38 TROUBLESHOOTING AND REP AIR F-38 POWER MIG® 215 OUTPUT CAP ACITORS REPLACEMENT (Continued) 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 wash[...]

  • Page 75

    F-39 TROUBLESHOOTING AND REP AIR F-39 POWER MIG® 215 OUTPUT CAP ACITORS REPLACEMENT (Continued) FIGURE F .15. - MOUNTING SCREW/BOL T LOCA TIONS } { 3/8" Nuts &  Lock washers  (3 places) Lead Mounti ng Bolts Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to [...]

  • Page 76

    F-40 NOTES F-40 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 77

    F-41 TROUBLESHOOTING AND REP AIR F-41 POWER MIG® 215 MAIN TRANSFORMER REPLACEMENT 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 or machine operator and will invalidate your factory warranty . For your safety and to a[...]

  • Page 78

    F-42 TROUBLESHOOTING AND REP AIR F-42 POWER MIG® 215 MAIN TRANSFORMER REPLACEMENT (Continued) 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 [...]

  • Page 79

    F-43 TROUBLESHOOTING AND REP AIR F-43 POWER MIG® 215 MAIN TRANSFORMER REPLACEMENT (Continued) 15. Carefully maneuver the main transformer out the left side of the machine. NOTE: T wo people may be needed to maneu- ver the main transformer out of the machine. REPLACEMENT 1. Carefully maneuver the new main trans- former back into the machine and ont[...]

  • Page 80

    F-44 TROUBLESHOOTING AND REP AIR F-44 POWER MIG® 215 MAIN TRANSFORMER REPLACEMENT (Continued) FIGURE F .18. - LEADS SWITCH LEADS FIGURE F .19. - LEAD 121 & 1 18 X8 X7 X6 X5 X4 X3 X2 Front - + 121 1 18 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return t[...]

  • Page 81

    F-45 TROUBLESHOOTING AND REP AIR F-45 POWER MIG® 215 MAIN TRANSFORMER REPLACEMENT (Continued) 5/16" Nut REAR ACCESS P ANEL FIGURE F .20. - REAR ACCESS P ANEL FIGURE F .21. - REAR ACCESS P ANEL (CLOSE-UP) 230V 208V 4 L1 L2 Lead 1 18 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T O[...]

  • Page 82

    F-46 NOTES F-46 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC[...]

  • Page 83

    F-47 TROUBLESHOOTING AND REP AIR F-47 POWER MIG® 215 F AN BLADE/MOTOR REPLACEMENT 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 or machine operator and will invalidate your factory warranty . For your safety and to a[...]

  • Page 84

    F-48 TROUBLESHOOTING AND REP AIR F-48 POWER MIG® 215 F AN BLADE/MOTOR REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver , remove the lower right side of the case wraparound cover . 2. Perform the Output Capacitor Bank Removal Procedure. 3. Using a 5/16” nutdriver , remove the four fan mounting screws from the rear of the machine. See[...]

  • Page 85

    F-49 TROUBLESHOOTING AND REP AIR F-49 POWER MIG® 215 OUTPUT CONT ACTOR REPLACEMENT 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 or machine operator and will invalidate your factory warranty . For your safety and to [...]

  • Page 86

    F-50 TROUBLESHOOTING AND REP AIR F-50 POWER MIG® 215 OUTPUT CONT ACTOR REPLACEMENT (Continued) 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 contactor . Note l[...]

  • Page 87

    F-51 TROUBLESHOOTING AND REP AIR F-51 POWER MIG® 215 OUTPUT CONT ACTOR REPLACEMENT (Continued) 7/16" Mounting Bolts FIGURE F .24. - OUTPUT CONT ACT OR MOUNTING BOL TS Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T [...]

  • Page 88

    F-52 TROUBLESHOOTING AND REP AIR F-52 POWER MIG® 215 RETEST AFTER REP AIR INPUT IDLE AMPS AND W A TTS OPEN CIRCUIT VOL T AGE WIRE SPEED RANGE Input V olts/Herts 230/60 Maximum Idle Amps 2.0 Maximum Idle Watts 150 35 - 40 VDC 50 - 700 IPM (1.27 - 17.8 m/minute) Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T[...]

  • Page 89

    POWER MIG® 215 G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM - COMPLETE MACHINE - CODE 1 1070 - (L1 1986) . . . . . . . . . . . . . . . . . . . . . G-2 W[...]

  • Page 90

    ElEcTrical DiaGramS G-2 pOWEr miG® 215 WiriNG DiaGram - cOmplETE machiNE - cODE 1 1070 - (l1 1986) POW ER M IG 2 15 (208/ 220 /230V ) J1 C AVIT Y NUM BE R IN G SE Q UENCE (COMPONENT S IDE OF P .C. B OARD) J2 NOTES: N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. N.B. THIS DIAGRAM S[...]

  • Page 91

    ElEcTrical DiaGramS G-3 pOWEr miG® 215 WiriNG DiaGram - cOmplETE machiNE - cODE 1 1099, 1 1247 - (l12184) POW ER M IG 21 5 (208 /22 0/230 V) FOR CODES 11 099 A ND 11 247 J1 C AVIT YN U M BE RING SE QUENCE (COMPONENT S IDE OF P .C. B OARD) J2 NOTES: N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE[...]

  • Page 92

    ElEcTrical DiaGramS G-4 pOWEr miG® 215 SchEma Tic - cOmplETE machiNE - cODE 1 1247 - (l12308 pG1) EN -168 S O L I D E D G E L12308 ENGINE ERING CONTROL L ED MANUFACTURER: No CHA NG E D ET A IL: NEW. L1230 8 POWER MI G 215 MACHINE SCHEMATIC NO NE - cstub le J. S KERBEC - DRA WN B Y: DE SI GN INFORM A TION E NGIN EE R: APPROVED: REFERENCE: EQU IP ME[...]

  • Page 93

    ElEcTrical DiaGramS G-5 pOWEr miG® 215 SchEma Tic - cOmplETE machiNE - cODE 1 1247 - (l12308 pG2) EN -168 S O L I D E D G E L 12308 ENGINE ERING CONTROL L ED MANUFACTURER: No CHA NG E D ET A IL: NEW. L1230 8 POWER MI G 215 MACHINE SCHEMATIC NO NE - cstub le J. S KERBEC - DRA WN B Y: DE SI GN INFORM A TION E NGIN EE R: APPROVED: REFERENCE: EQU IP M[...]

  • Page 94

    ElEcTrical DiaGramS G-6 pOWEr miG® 215 SchEma Tic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 1 1070 - (G3850 pG1) G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to M[...]

  • Page 95

    ElEcTrical DiaGramS G-7 pOWEr miG® 215 SchEma Tic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 1 1070 - (G3850 pG2) G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to M[...]

  • Page 96

    ElEcTrical DiaGramS G-8 pOWEr miG® 215 SchEma Tic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 1 1070 - (G3850 pG3) G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to M[...]

  • Page 97

    ElEcTrical DiaGramS G-9 pOWEr miG® 215 SchEma Tic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 1 1099, 1 1247 - (G4414 pG1) G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Ret[...]

  • Page 98

    ElEcTrical DiaGramS G-10 pOWEr miG® 215 SchEma Tic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 1 1099, 1 1247 - (G4414 pG2) G-10 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC R[...]

  • Page 99

    ElEcTrical DiaGramS G-11 pOWEr miG® 215 SchEma Tic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 1 1099, 1 1247 - (G4414 pG3) G-11 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC R[...]