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. DOꢀNOT 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
Copyright © Lincoln Global Inc.
• 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 WEBꢀSITE: www.lincolnelectric.com
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ii
ii
SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
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
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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iii
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SAFETY
WELDING and CUTTING
SPARKS can cause fire or
explosion.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
6.a. Remove fire hazards from the welding area.If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
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 position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
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.
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iv
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque d’incendie dû aux étincelles.
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:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés 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
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Power MIG® 215XT
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v
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SAFETY
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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vi
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SAFETY
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-
1
tions.
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”
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I
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-580
Power MIG® 215XT
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A-1
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Output Polarity Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Power MIG® 215XT
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS – POWER MIG® 215XT
INPUT – SINGLE PHASE ONLY
Standard Voltage/Phase/Frequency
Input Current @ 170 Amp Rated Output Input Current @ 215 Amp Rated Output
208/230/1/50/60 Hz
(With 115V receptacle loaded to 15A)
39/35 Amps
(With 115V receptacle loaded to 15A)
45/41 Amps
RATED OUTPUT
Amps
Duty Cycle
30%
Volts at Rated Amperes
22 Volts
215 Amps
190 Amps
170 Amps
40%
23 Volts
60%
24 Volts
OUTPUT
Welding Current Range
Maximum Open Circuit Voltage
Welding Voltage Range
30 – 250Amps
35 Volts
13.5-24 Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES
75°C Copper Wire
75°C Copper Wire
in Conduit
AWG (IEC) Sizes
(For lengths
exceeding 100 ft.)
Input Ampere
Rating On
Nameplate
in Conduit
AWG (IEC) Sizes
(For lengths
Input Voltage/
Frequency (Hz)
Fuse or Breaker
Size (Super Lag)
up to 100 ft.)
2
2
2
2
208/50/60
230/50/60
60
60
45A
41A
10 (6 mm )
10 (6 mm )
8 (10 mm )
8 (10 mm )
NOTE: Use #10 AWGꢀGrounding Wire
WIRE SPEED RANGE
Wire Speed
50 – 700 IPM (1.27 – 17.8 m/minute)
PHYSICAL DIMENSIONS
Width
Height
Depth
Weight
31.79 in
808 mm
18.88 in
480 mm
38.78 in
985 mm
210 Ibs
95 kg
TEMPERATURE RANGES
STORAGE TEMPERATURE RANGE
-40°F to 185°F(-40°C to +40°C)
OPERATING TEMPERATURE RANGE
-4°F to 104°F(-20°C to +40°C)
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A-3
A-3
INSTALLATION
Read entire installation section before starting
installation.
INPUT POWER, GROUNDING AND
CONNECTION DIAGRAMS
SAFETY PRECAUTIONS
WARNING
WARNING
ELECTRIC SHOCK can kill.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as
output terminals or internal wiring.
• Only qualified personnel should
perform this installation.
• All input power must be electrically dis-
connected before proceeding.
• Only personnel that have read
and understood the POWER
MIG® 215XT Operating Manual
should install and operate this
equipment.
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.
• 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
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.
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.
WARNING
Make certain that the input power is electrically
disconnected before removing the screw on the
reconnect panel access cover.
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.
------------------------------------------------------------------------
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A-4
A-4
INSTALLATION
FIGURE A.1 — Dual Voltage Machine Input Connections
50/60 HZ
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.
OUTPUT POLARITY CONNECTIONS
The welder, as shipped from the factory, is connected
for electrode positive (+) polarity. This is the normal
polarity for GMA welding.
4. Using the instructions in Figure A.2, have a qualified
receptacle (Customer
electrician connect
a
Supplied) or cable to the input power lines and the
system ground per the U.S. National Electrical
Code and any applicable local codes. See
“Technical Specifications” at the beginning of this
chapter for proper wire sizes. For long runs over
100 feet, larger copper wires should be used. Fuse
the two hot lines with super lag type fuses as shown
in the following diagram. The center contact in the
receptacle is for the grounding connection. A green
wire in the input cable connects this contact to the
frame of the welder. This ensures proper grounding
of the welder frame when the welder plug is insert-
ed into a grounded receptacle.
If negative (–) polarity is required, interchange the con-
nection of the two cables located in the wire drive com-
partment near the front panel. The electrode cable,
which is attached to the wire drive, is to be connected
to the negative (–) labeled terminal and the work lead,
which is attached to the work clamp, is to be connect-
ed to the positive (+) labeled terminal.
FIGURE A.2 — Receptacle Diagram
CONNECT TO A SYSTEM
GROUNDING WIRE. SEE
THE UNITED STATES
NATIONAL ELECTRICAL
CODE AND/OR LOCAL
CODES FOR OTHER
DETAILS AND MEANS FOR
PROPER GROUNDING.
CONNECT TO HOT WIRES
OF A THREE-WIRE, SINGLE
PHASE SYSTEM.
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A-5
A-5
INSTALLATION
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.
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.
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.
WARNING
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.
Turn the welder power switch off before installing
gun and cable.
1. Lay the cable out straight.
WARNING
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.
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.
Make sure connector is fully inserted and tighten
knurled screw.
4. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench.
NOTE: If connecting to 100% CO cylinder, an
2
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
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.
to the CO cylinder.
2
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.
SHIELDING GAS
(For Gas Metal Arc Welding Processes)
Customer must provide cylinder of appropriate type
shielding gas for the process being used.
6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.
A gas flow regulator, for Argon blend gas, and an inlet
gas hose are factory provided with the POWER MIG®
215XT. When using 100% CO an additional adapter
will be required to connect the regulator to the gas bot-
tle.
2
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
CYLINDER may explode if
damaged.
WARNING
Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
stand to one side.
• 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.
------------------------------------------------------------------------
8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making the weld.
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.
AUXILIARYꢀPOWERꢀRECEPTACLES
(15 Amp 120ꢀVolt Receptacle) The receptacles are UL
and CSAꢀapproved.
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A-6
A-6
NOTES
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B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Wire Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Wire Size Conversion parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Procedure for Changing Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Wire Reel Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Mounting of 10 to 30 lbs. Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
To Start the Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Feeding Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Wire Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5, B-6
Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Welding Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Welding Procedure Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
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B-2
B-2
OPERATION
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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B-3
B-3
OPERATION
LIMITATIONS
PRODUCT DESCRIPTION
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.
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.
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.
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.
FIGURE B.1
RECOMMENDED PROCESSES AND
EQUIPMENT
3
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-
2
1
®
®
minum, .035 (0.9 mm), .045" (1.2 mm) Outershield
®
and .045”(1.2mm) Ultracore as well as .035" (0.9
®
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)
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.
5. 4-Pin Connector-For Spool Gun Operation.
FIGURE B.1a
5
4
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.
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B-4
B-4
OPERATION
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.
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
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.
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.
9. Slide cage all the way onto the adapter until the retaining
spring "pops up" fully.
PROCEDURE FOR CHANGING
DRIVE ANDꢀIDLE ROLL SETS
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.
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.1
2 IN, O.D. SPINDLE
ADAPTER
RETAINING SPRING
FIGURE B.2
BRAKE
HOLDING
PIN
RETAINING
GROOVES
COLLAR
LOCKED POSITION
UNLOCKED POSITION
READI-REEL
5. Remove the inside wire guide plate.
INSIDE CAGE WIRES
RELEASE
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.
BAR
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.
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:)
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B-5
B-5
OPERATION
The pressure arm controls the amount of force the drive
rolls exert on the wire. Proper adjustment of both pressure
arm gives the best welding performance. For best results,
set both pressure arms to the same value.
TO START THE WELDER
Turn the “Power Switch” switch to “ON”. With the desired voltage
and wire speed selected, operate the gun trigger for welder output
and to energize the wire feed motor.
FEEDING WIRE ELECTRODE
WARNING
Set the pressure arm as follows (See Figure B.2a):
Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6
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.
FIGURE B.2a
------------------------------------------------------------------------
NOTE: Check that drive rolls, guide plates and gun
parts are proper for the wire size and type
section.
C ORED WIR ES
SOLID WIRES
1
3
5
ALUMINUM
2
4
6
OU TER SHIELD
METALSHIELD
INNERS HIELD
1. Turn the Readi-Reel or spool until the free end of the
electrode is accessible.
STEEL
STAINLESS
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).
WIRE DRIVE CONFIGURATION
(See Figure B.2b)
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.
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.
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.
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.
• 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.
------------------------------------------------------------------------
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B-6
B-6
OPERATION
5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.
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
Important: Do not attempt to completely
remove the socket head cap screw.
®
contact tip [3/4" (20 mm) for Outershield ].
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.
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”.
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.
WARNING
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.
• When using an open arc process, it
is necessary to use correct eye,
head, and body protection.
-----------------------------------------------------------------------
10. Tighten the socket head cap screw.
6. Position electrode over joint. End of electrode may
be lightly touching the work.
11. Insert the welding gun into the gun bushing and
tighten the thumb screw.
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
MAKING A WELD
®
1. Check that the electrode polarity is correct for the
process being used, then turn the power switch
ON.
Outershield ].
8. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
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.
Figure B.2b
THUMB SCREW
GUN RECEIVER BUSHING
OUTER WIRE GUIDE
CONNECTOR BLOCK
SOCKET HEAD
CAP SCREW
LOOSEN
TIGHTEN
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B-7
B-7
OPERATION
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.
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.
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.
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.
AVOIDING WIRE FEEDING
PROBLEMS
Wire feeding problems can be avoided by observing
the following gun handling procedures:
WIRE FEED OVERLOAD
PROTECTION
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.
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.
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.
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.
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.
PROCEDURE CHART
Wire Feed Speed/Voltage Tap Settings
Wire Dia. Gas Type Wire Type Polarity 18 gage 16 gage14 gage 12 gage10gage 3/16 1/4 5/16 3/8 1/2
†
Outershield 1" CTWD
.035
.035
.045
75Ar/25CO OS71M
DC+
DC+
DC+
250/D 300/E 350/F 500/G *500/G
300/E 350/F 500/G
2
100%CO
OS71M
2
75Ar/25CO OS71M
200/E 225/F 250/G 250/G *250/G
2
†
Innershield 5/8" CTWD
.035
.045
.045
NoneReq’d NR-211MP
NoneReq’d NR-211MP
NoneReq’d NR212
DC-
DC-
DC-
50/B
40/B
70/B
50/B
80/B
60/B
90/C
50/B
65/C
100/C
70/C
70/C
90/C 110/D **130/E
90/C 110/D *130/E *150/E *150/E
†
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"
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B-8
B-8
NOTES
Power MIG® 215XT
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C-1
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Aluminum Feeding Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
K363P Readi-Reel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Dual Cylinder Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Alternative Magnum GMAW Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Magnum Gun Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Optional Spool Guns and Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Make a Weld with the Magnum 250LX Push-Pull Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
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C-2
C-2
ACCESSORIES
ALTERNATIVE MAGNUM GMAW
GUN AND CABLE ASSEMBLIES
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.
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:
TABLE C.1
Wire
Size
Drive Roll Kit
.023”-.030” (0.6-0.8 mm)
.035” (0.9 mm)
.045” (1.2 mm)
.035-.045 (0.9-1.2mm)
.040 (1.01)
KP1696-030S
KP1696-035S
KP1696-045S
KP1696-1
English Wire
Size
Metric Wire
Size
Length
Part No.
Solid
Steel
10' (3.0 m)
12' (3.6 m)
15' (4.5 m)
K533-1
K533-7
K533-3
.035 – .045"
0.9 – 1.2 mm
KP1696-2
.035” (0.9 mm)
.045” (1.2 mm)
KP1697-035C
KP1697-045C
WARNING
Cored
• Unplug or Disconnect all input
power from the POWER MIG® 215XT
before installing the Spool Gun and
Kit.
Aluminum
3/64” (1.2 mm)
KP1695-3/64A
3/64" (1.2 mm) ALUMINUM
FEEDING KIT (K1703-1)
------------------------------------------------------------------------
MAGNUM GUN CONNECTION KIT
(Optional K466-6)
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.
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.
Kit includes drive rolls and wire guide plate for the wire
drive, liner and two contact tips for the gun, along with
installation instructions.
OPTIONAL SPOOL GUNS AND
ADAPTERS
The Power MIG® 215XT is capable of operating with the fol-
lowing optional spool guns:
READI-REEL ADAPTER (K363P)
SPOOL GUN
RATING
ADAPTER
The K363P Readi-Reel Adapter mounts to the 2" spin-
dle. It is needed to mount the 22-30 lb. Readi-Reels.
Magnum 100SG
(K2532-1)
Magnum SG
(K487-25)
Magnum 250LX
(K2490-1)
Light Duty
Factory Capable
130amp 30% Duty Cycle No Adapter Required
Medium Duty
250Amp 60% Duty Cycle Spool Gun Adapter
Heavy Duty
300 Amp 60% Duty Cycle
DUAL CYLINDER MOUNTING KIT
(K1702-1)
K2703-1
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.
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.
SMALL SPOOL SPINDLE ADAPTER
(K468)
The K468 spindle adapter allows the use of 8" diame-
ter small spools.
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C-3
C-3
ACCESSORIES
See Figure C.1
1. Plug the 115 VAC cable into available 115V AC recep-
MAGNUM 250LX PUSH-PULL GUN
AND PUSH PULL ADAPTER
®
tacle. The Power MIG 215XT (K2701-1) furnishes
the 15A 115V AC auxiliary supply. The receptacle is
located at the back of the machine.
For heavier duty aluminum applications when use of large
16 pound aluminum spools of wire are desired the follow-
ing push pull gun and adapter kit are available.
2. Connect the 4-pin connector cable of the Push-Pull
Gun Adapter to the 4-pin trigger receptacle located in
the front section of the wire drive compartment.
3. Connect the 7-pin connector cable of the Push-Pull
Gun to the 7-pin receptacle cable from the adapter.
4. Connect the Push-Pull gas & power pin into the Power
Magnum 250LX Push Pull Gun (K2704-1)
This pistol grip push pull gun is similar to the Magnum
250LX spool gun except it is designed to feed large
spools of wire. The Magnum 250LX push pull features a
25 foot power, gas and control cable. It operates as an
assist slave motor pulling the aluminum wire as the Power
MIG® drive motor acts as the master push motor.
®
MIG wire feeder brass bushing.
5. Attach a gas hose from the Gas supply to the rear inlet
®
gas fitting on the Power MIG 215XT
Magnum 250LX Push Pull Adapter (K2705-1)
MAKE A WELD WITH THE MAGNUM
250LX PUSH-PULL GUN
This adapter box is designed to drive the Magnum 250LX
push pull gun when used on a non push ready Lincoln
power source feeder such as the Power MIG® 215XT or
255XT. This box features a 115V cord and plug to power
the box, a control cable with receptacle to connect the
push pull gun’s control cable to, and a 4-pin connector to
connect to the Power MIG® gun trigger receptacle.
®
1. Power MIG 215XT
a. Set machine to non spool gun operation.
®
b. Turn the Power MIG 215XT input power ON.
c. Adjust the voltage control at the front panel.
d. Adjust the wire speed control on the front panel.
Refer to the procedure decal mounted at the inside
of the wire feeder compartment cover.
Note the Magnum 250LX push pull gun has a wire feed
speed adjustment potentiometer. However this poten-
tiometer only functions on push-pull ready machines like
the Power MIG® 350MP. When the Magnum 250LX is
used on a non-push-pull machine with the K2705-1
adapter, the wire feed speed is set on the control panel of
the machine.
2. Magnum 250LX Push-Pull Gun:
a. Set machine to non spool gun operation.
b. Closing Push-Pull gun trigger starts the Push-Pull
gun welding and makes all guns connected to the
machine electrically “Hot”.
c. The Push-Pull Adapter will provide power and con-
trol to the “Pull” motor of the Push-Pull gun & the
CONNECTING THE MAGNUM 250LX
PUSH-PULL GUN (K2704-1) AND
MAGNUM 250LX PUSH-PULL GUN
ADAPTER (K2705-1)
®
Power MIG 215XT will control its wire drive.
FIGURE C.1
4-PIN
CABLE
CONNECTOR
MAGNUM 250LX
PUSH-PULL GUN
7-PIN
CABLE
CONNECTORS
ADAPTER
PLUG INTO
AVAILABLE 120VAC
POWER SOURCE
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C-4
C-4
ACCESSORIES
4. Refer to the procedure decal on the Power MIG®
for initial aluminum settings. Make a test weld to
determine the final settings.
MAKING A WELD WITH THE SPOOL GUN
ADAPTER KIT AND SPOOL GUN
INSTALLED
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.
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.
•
•
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.
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D-1
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Drive Rolls and guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Contact Tip and Gas Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Gun Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
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D-2
D-2
MAINTENANCE
•
Be sure the nozzle insulator is fully screwed
onto the gun tube and does not block the gas
holes in the diffuser.
SAFETY PRECAUTIONS
WARNING
•
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.
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
• 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.
• 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.
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.
The fan motors have sealed ball bearings which
require no service.
GUN CABLE CLEANING
DRIVE ROLLS AND GUIDE PLATES
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.
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.
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.
For instructions on replacing or changing drive roll,
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.
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D-3
D-3
MAINTENANCE
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.)
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.
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.
TABLE D.1
Fixed
Nozzle
Adjustable
Nozzle
Replacement Size Stencilled Gas Diffuser Gas Diffuser
FIGURE D.1
Diameter of
Electrodes Used
Liner Part
Number
on End of
Liner Bushing (and Stencil) and Stencil)
Part No.
Part No.
SET SCREW
BRASS CABLE CONNECTOR
1-1/4"ꢀ
.025-.030" Steel
(0.6-0.8 mm)
KP1934-2
KP1934-1
KP1955-1
.030 (0.8 mm)
.045 (1.2 mm)
KP2026-3
KP2026-3
KP2026-2
KP2026-2
KP2026-2
(31.8mm)ꢀ
LINERꢀ
TRIMꢀ
.035-.045" Steel
(0.9-1.2 mm)
LENGTH
3/64" Aluminum
(1.2 mm)
3/64" (1.2 mm) KP2026-3
SET SCREW
GAS DIFFUSER
NOZZLE INSULATOR (IF USED)
GAS NOZZLE
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.
CAUTION
This screw should only be gently tightened.
Overtightening will split or collapse the liner and
cause poor wire feeding.
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.
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D-4
D-4
MAINTENANCE
TABLE D.2
ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS
FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES
GUN HANDLE DISASSEMBLY
The internal parts of the gun handle may be
inspected or serviced if necessary.
English
Size
Metric
Size
Description
Part No.
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.
CABLE LINER
For 15' (4.5 m) or
shorter Cable
KP1934-2
KP1934-1
KP1955-1
.025 – .030"
.035 – .045"
3/64"
0.6 – 0.8 mm
0.9 – 1.2 mm
1.2 mm
(Alum. wire)
(Alum. wire)
CONTACT TIPS
Standard Duty
KP2020-6B1
KP2020-7B1
.025"
.030"
.035"
.045"
.035"
.045"
.025"
.030"
.035"
0.6 mm
0.8 mm
KP2020-1B1*
KP2020-2B1
KP2021-1B1
KP2020-2B1
KP2022-5B1
KP2022-6B1
KP2022-1B1
KP2022-2B1
KP2010-5B1
0.9 mm
1.2 mm
0.9 mm
1.2 mm
0.6 mm
0.8 mm
0.9 mm
1.2 mm
1.2 mm
(Alum. Wire)
Heavy Duty
Tapered
.045"
3/64"
(Alum. Wire)
Tab (For Aluminum)
GAS NOZZLES
Fixed (Flush)
KP1931-1
KP1931-2 *
KP1931-3
KP1930-1
KP1930-2
KP1930-3
3/8"
1/2"
5/8"
3/8"
1/2"
5/8"
9.5 mm
12.7 mm
15.9 mm
9.5 mm
12.7 mm
15.9 mm
Counterclockwise
Fixed (Recessed)
Requires: Gas
Diffuser As'bly
KP2026-3 *
.025 – .045"
0.6 – 1.2 mm
Adjustable Slip-On
Requires:
KP1935-2
KP1935-1
1/2"
5/8"
12.7 mm
15.9 mm
Nozzle Insulator KP2025-1
As’bly
Requires:
Gas Diffuser
As’bly
KP2026-2
KP2026-1
.025 – .030"
.035 – .045"
0.6 – 0.8 mm
0.9 – 1.2 mm
Gasless Nozzle
(For Innershield)
KP1947-1 ∆
GUN TUBE ASSEMBLIES
Standard (60°)
45°
KP2015-1 *
KP2041-1
*
∆
Included with POWER MIG® 215XT
Requires KP2026-1 Gas Diffuser Assembly.
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D-6
D-6
NOTES
Power MIG® 215XT
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Wirefeed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
FIGURE E.1 BLOCK LOGIC DIAGRAM
SPOOL
GUN
WIRE
SPEED
GAS
SOLENOID
SWITCH
CONTROL
WIRE
DRIVE
MOTOR
CIRCUIT
115V
CONTROL BOARD
BREAKER RECEPTACLE
FAN
MOTOR
TRANSFORMER
THERMOSTAT
OUTPUT BRIDGE
THERMOSTAT
TACH
FEEDBACK
GUN TRIGGER
LINE
SWITCH
TAP SELECTOR
SWITCH
GUN
ASSEMBLY
OUTPUT DIODE
BRIDGE
+
+
POSITIVE
TERMINAL
OUTPUT
CHOKE
OUTPUT
CAPACITORS
CONTACTOR
-
-
RECONNECT
PANEL
MAIN
TRANSFORMER
NEGATIVE
TERMINAL
Power MIG® 215XT
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 - INPUT POWER CIRCUIT
SPOOL
GUN
WIRE
SPEED
GAS
SOLENOID
SWITCH
CONTROL
WIRE
DRIVE
MOTOR
CIRCUIT
115V
CONTROL BOARD
BREAKER RECEPTACLE
FAN
MOTOR
TRANSFORMER
THERMOSTAT
OUTPUT BRIDGE
THERMOSTAT
TACH
FEEDBACK
GUN TRIGGER
LINE
SWITCH
TAP SELECTOR
SWITCH
GUN
ASSEMBLY
OUTPUT DIODE
BRIDGE
+
+
POSITIVE
TERMINAL
OUTPUT
CHOKE
OUTPUT
CAPACITORS
CONTACTOR
-
-
RECONNECT
PANEL
MAIN
TRANSFORMER
NEGATIVE
TERMINAL
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
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E-3
E-3
THEORY OF OPERATION
FIGURE E.2 - CONTROL CIRCUITS
SPOOL
GUN
WIRE
SPEED
GAS
SOLENOID
SWITCH
CONTROL
WIRE
DRIVE
MOTOR
CIRCUIT
115V
CONTROL BOARD
BREAKER RECEPTACLE
FAN
MOTOR
TRANSFORMER
THERMOSTAT
OUTPUT BRIDGE
THERMOSTAT
TACH
FEEDBACK
GUN TRIGGER
LINE
SWITCH
TAP SELECTOR
SWITCH
GUN
ASSEMBLY
OUTPUT DIODE
BRIDGE
+
+
POSITIVE
TERMINAL
OUTPUT
CHOKE
OUTPUT
CAPACITORS
CONTACTOR
-
-
RECONNECT
PANEL
MAIN
TRANSFORMER
NEGATIVE
TERMINAL
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
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E-4
E-4
THEORY OF OPERATION
FIGURE E.2 - OPTIONAL CIRCUITS
SPOOL
GUN
WIRE
SPEED
GAS
SOLENOID
SWITCH
CONTROL
WIRE
DRIVE
MOTOR
CIRCUIT
115V
CONTROL BOARD
BREAKER RECEPTACLE
FAN
MOTOR
TRANSFORMER
THERMOSTAT
OUTPUT BRIDGE
THERMOSTAT
TACH
FEEDBACK
GUN TRIGGER
LINE
SWITCH
TAP SELECTOR
SWITCH
GUN
ASSEMBLY
OUTPUT DIODE
BRIDGE
+
+
POSITIVE
TERMINAL
OUTPUT
CHOKE
OUTPUT
CAPACITORS
CONTACTOR
-
-
RECONNECT
PANEL
MAIN
TRANSFORMER
NEGATIVE
TERMINAL
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
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E-5
E-5
THEORY OF OPERATION
PROTECTIVE DEVICES AND CIRCUITS
THERMAL AND OVERLOAD PROTECTION WIREFEED OVERLOAD PROTECTION
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 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.
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.
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E-6
E-6
NOTES
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F-1
F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11
Main Transformer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11
Wire Drive Motor and Tachometer Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Output Bridge Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21
Voltage Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27
Wire Drive Motor Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Output Diode Bridge Rectifier Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
Output Capacitors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37
Fan Blade/Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47
Output Contactor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49
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.
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F-2
F-2
TROUBLESHOOTING AND REPAIR
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.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
Course of Action” lists the most likely com-
procedure listed below.
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.
Step 1. LOCATE PROBLEMꢀ(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.
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.
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.
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.
-----------------------------------------------------------------------------------------------------------------------------------
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F-3
F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING 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.
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.
- 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.
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:
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.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
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:
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.
- Remove your body’s static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
equipment frame.
grounded part of the
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
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.
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical
damage is evident.
1. Contact Lincoln Electric Service
Department 1-888-935-3877.
1. Contact your local Lincoln
Electric authorized field service
facility.
The machine is dead--no open 1. Make certain the input power 1. Check the input power switch
circuit voltage and no wire feed
when the gun trigger is activated.
The cooling fan is not running.
switch (S1) is in the “ON”
position.
(S1). It may be faulty.
2. Check for broken or missing
wires at the reconnect panel.
2. Check the input voltage at the
machine. The input voltage
must match the rating plate and
the reconnect panel.
3. Perform the Main Transformer
3. Check for blown or missing
fuses in the input lines.
There is no open circuit voltage or 1. Make sure the input voltage is 1. The baffle mounted rectifier
wire feed when the gun trigger is
activated. The cooling fan is
running.
correct and matches the
nameplate rating and reconnect
panel configuration.
bridge may be faulty. Check
and replace if necessary.
2. Perform the Main Transformer
2. One of the two thermostats may
be open due to machine
overheating. If the machine
3. Check the thermostats and
associated leads for loose or
faulty connections. See the
Wiring Diagram.
operates normally after
a
cooling off period then check for
proper fan operation and
ventilation. Make certain the
machine’s duty cycle is not
being exceeded.
4. The
internal
triggering
circuit/plugs may be faulty. See
the Wiring Diagram.
5. The control board may be faulty.
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.
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F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
(continued from previous page)
3. Check the gun trigger leads.
Leads #324 to #325 should have
continuity (zero ohms) when the
gun trigger is activated. If not,
the gun trigger or cable may be
faulty. Check or replace.
4. Check to make sure the switch
on the Magnum 100SG Adapter
Panel is in the Magnum Push
Gun Position.
5. If a spool gum option kit is
installed, check to make sure it is
set to the “normal” position if
using the Power MIG® 215XT
built in wire feeder.
When the gun trigger is activated 1. Make sure the gun cable and 1. Check the output selector
switch for proper operation and
good connections.
and the wire feeds normally, but
there is no open circuit voltage.
work cables are connected prop-
erly and in good condition.
switch is in a good condition posi-
tion and not between positions.
5. Check the heavy current carry-
ing leads between the output
selector switch, output contac-
tor, output bridge rectifier, and
the output terminals for loose or
faulty connections. See Wiring
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.
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Output voltage and wire feed speed 1. Remove the gun assembly. If the 1. Check for “shorts” in the trigger
is present when the gun trigger is
NOTꢀactivated.
problem is resolved, the gun
assembly is faulty. Repair or
replace. If the problem is NOT
resolved, the fault is within the
Power MIG® 215XT machine.
circuitry within the Power MIG®
215XT machine.
Wiring Diagram.
See the
2. The control board may be faulty.
The machines output is low. Welds 1. Check the input voltage. Make 1. Check for loose or faulty con-
are “cold”. The weld beads are
rounded or “humped” demonstrat-
ing poor wetting into the plate. The
machine cannot obtain full rated
output of 200 amps at 22VDC.
sure the machine is configured
properly for the input voltage
being applied.
nections on the heavy current
carrying leads inside the Power
MIG® 215XT. See the Wiring
Diagram.
2. Make sure the settings for wire
feed speed and voltage are cor- 2. The output capacitors may be
rect for the process being used.
faulty. Check for loose connec-
tions at the capacitors. Also
check for leaky capacitors.
Replace if necessary.
3. Make sure the electrode polarity
is correct for the process being
used.
WARNING: The liquid electrolyte
4. Check the welding cables and in these capacitors is toxic.
gun for loose or faulty connec- Avoid contact with any portion of
tions.
your body.
3. The output selector switch may
be faulty. Check for good con-
tact and continuity (zero ohms)
through the switch. See the
Wiring Diagram.
when the gun trigger is NOT acti-
vated. The wire feed functions nor-
mally.
stuck closed.
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.
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
There is no gas flow when the gun 1. If a spool gun adapter is installed, 1. Check plug J1 on the control board
trigger is activated . The wire feeds
and the arc voltage is present.
make certain the toggle switch in
the spool gun kit in the correct
position.
for loose or faulty connections. See
Wiring Diagram.
2. Check the gas solenoid by discon-
necting it from leads #108A and
#116A&B. Apply a 12VDC external
supply to the solenoid. If the sole-
noid does NOT activate then it may
be faulty. Replace.
2. Check to make sure the switch on
the Magnum 100SG Adapter
Panel is in the Magnum Push
Gun Position.
3. Check the gas source and hoses
for kinks or leaks.
The machine stops feeding wire 1. Check for a mechanical restriction 1. Check the motor armature current.
while welding. When the gun trig-
ger is released and pulled again,
the wire feed starts.
in the wire feed path. The gun
may be clogged.
Normal armature current is 2.0 to 2.7
amps maximum. If the motor arma-
ture current is normal, and the motor
continues to shut-off, the control
board may be faulty. Replace.
2. Make sure the drive rolls and
guide plates are clean and are the
correct size.
2. If the motor armature current is high
(over 2.7 amps) and there are NO
restrictions in the wire feeding path
then the motor or gearbox may be
defective. Replace.
3. Check the spindle for ease of rota-
tion.
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.
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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
Rough wire feeding or the wire will 1. The gun cable may be kinked or
not feed but the drive rolls are turn-
ing.
twisted.
2. Check the drive roll tension and
the position of the grooves.
3. Electrode may be rusted or dirty.
4. The contact tip may be damaged
or not the correct size.
5. Check the wire spindle for ease of
rotation.
6. Make certain the gun is pushed
all the way into the gun mount
and properly seated.
No control of wire feed speed. 1. The wire feed speed control may 1. The wire speed control potentiome-
Other machine functions are nor-
mal.
be dirty. Rotate several times and
check if the problem is resolved.
ter may be faulty. Check or replace.
Normal potentiometer resistance is
10K ohms.
2. Perform the Wire Drive Motor and
3. The control board may be faulty.
There is no wire feed when the gun 1. Check for adequate wire supply.
trigger is activated. Normal open
circuit weld voltage is present and 2. If the drive rolls are turning, check
1. Perform the Wire Drive Motor and
the gas solenoid functions normal-
ly.
for a mechanical restriction in the 2. The wire speed control potentiome-
wire feed path.
ter may be faulty. Check or replace.
Normal potentiometer resistance is
10K ohms.
3. The gun liner may be clogged.
Check or replace.
3. The control board may be faulty.
4. If the drive rolls are not turning
when the gun trigger is activated,
contact your local Lincoln Electric
Authorized Field Service Facility.
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.
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F-9
Observe Safety Guidelines detailed in the beginning of this manual.
F-9
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Poor arc striking with electrode 1. Make sure the settings for wire 1. The output capacitors may be faulty.
sticking or blasting off.
feed speed and voltage are cor-
rect for the process being used.
Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.
2. Make certain the gas shielding is
correct for the process being WARNING: The liquid electrolyte in
used.
these capacitors is toxic. Avoid
contact with any portion of your
3. Make sure the machine’s recon- body.
nect panel is configured properly
applied.
The arc is unstable and or “hunting” 1. Check for a worn or melted con- 1. Check for loose or faulty connections
tact tip.
at the output terminals, choke, out-
put capacitors, output selector
switch, output contactor, and all
heavy current carrying leads. See
the Wiring Diagram.
2. Check for loose or faulty connec-
tions on the work and gun cables.
3. Make sure the electrode polarity is
correct for the welding process 2. Check the output selector switch for
being used.
proper operation and good connec-
tions.
4. Check for rusted or dirty electrode
wire.
3. The output capacitors may be faulty.
Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.
5. Make sure the machine’s settings
and shielding gas are correct for
the process being used.
WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid con-
tact with any portion of your body.
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
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F-10
Observe Safety Guidelines detailed in the beginning of this manual.
F-10
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
May have porosity with the elec-
trode stubbing into the plate.
dures and electrode polarity are
correct for the process being
used.
2. The output capacitors may be faulty.
Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.
2. Make certain the shielding gas is
correct and the flow is proper.
3. Make sure the weld joint is not WARNING: The liquid electrolyte in
“contaminated”.
these capacitors is toxic. Avoid
contact with any portion of your
body.
The contact tip seizes in the gas dif- 1. The tip is being over heated due
fuser.
to excessive current and/or high
duty cycle.
2. A light application of high temper-
ature anti-seize lubricant may be
applied to the contact tip threads.
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
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F-11
F-11
TROUBLESHOOTING AND REPAIR
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
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F-12
F-12
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER TEST (continued)
FIGURE F.1 – OUTPUT SELECTOR SWITCH TERMINALS
X4 X5
X3
X6
X2
X7
X8
7. Connect main input power to the machine.
PROCEDURE
8. Turn the Power MIG®ꢀ215XT ON/OFF Power
Switch to the ON position.
WARNING
THE ON/OFF POWER SWITCH will be “hot”
during these tests.
WARNING
ELECTRIC SHOCK can kill.
NOTE: Secondary
voltages
will
vary
proportionately with the primary input
• Do not touch electrically live parts
such as output terminals or inter-
nal wiring.
voltage.
1. Disconnect the main input power supply to the
machine.
• All input power must be electrical-
ly disconnected before proceed-
ing.
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.
10. Turn Off the machine.
5. Locate lead X1 located on the output rectifier
11. If any of the voltages are incorrect or missing,
check for loose or broken connections between
the main transformer and the test points.
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F-14
F-14
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER TEST (continued)
TABLE F.1 – TEST POINTS
INPUT VOLTAGE
230 VAC
TEST POINTS
X1-X2
EXPECTED VOLTAGE READING
11.9-13.0 VAC
14.1-15.2 VAC
16.2-17.5 VAC
18.4-19.7 VAC
20.5-22.0 VAC
22.7-24.2 VAC
24.8-26.5 VAC
26.9-28.8 VAC
230 VAC
X1-X3
X1-X4
230 VAC
230 VAC
230 VAC
230 VAC
230 VAC
230 VAC
X1-X5
X1-X6
X1-X7
X1-X8
X9-X10
12. If ALL the voltages tested are incorrect or miss-
ing, test for correct nameplate input voltage
between the H1 lead at the ON/OFFꢀPOWER
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.
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.
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/OFFꢀPOWER SWITCH for proper
operation.
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F-15
F-15
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK 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 Wire Drive Motor and Voltage Feedback Circuit are
functioning properly.
MATERIALS NEEDED
5/16” Nutdriver
Volt-Ohmmeter
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F-16
F-16
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)
FIGURE F.4 – PLUG J4
Black
Tach
Black
Arm
White
Arm
J11
Blue
Tach
Red
Tach
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.
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F-17
F-17
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)
5. Make the following voltage tests:
TEST FOR SUPPLY VOLTAGE TO TACHOME-
TER
WARNING
1. Disconnect the main AC input power to the
machine.
ELECTRIC SHOCK can kill.
2. Locate plug J4.
• Do not touch electrically live parts
such as output terminals or internal
wiring.
• All input power must be electrically
disconnected before proceeding.
4. Connect the main input power to the machine.
5. Make the following voltage tests:
a. Turn the machine OFF between each test.
WARNING
b. Carefully insert the meter probes into the lead
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
such as output terminals or internal
wiring.
c. Turn the machine ON and pull the gun trigger
to conduct the voltage test.
• All input power must be electrically
disconnected before proceeding.
FROM LEAD
FROM LEAD
FROM LEAD
Black
Armature
Lead
White
Armature
Lead
2-29 VDC
(varies depending
on wire feed
speed)
a. Turn the machine OFF between each test.
b. Carefully insert the meter probes into the
lead side of plug J4.
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.
FROM LEAD
FROM LEAD
FROM LEAD
Black (-)
Red (+)
5-6 VDC
7. If all wires and connectors are good and the volt-
age to the drive motor armature is zero, the con-
trol PCꢀboard may be faulty. Replace the control
PC board.
6. If the 5-6 VDC is present, check the leads to the
tachometer circuit.
8. If the motor is running at high speed and the
armature voltage is high and uncontrollable,
Proceed with the tachometer test.
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.
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F-18
F-18
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)
FIGURE F.5 – PLUG J4
Blackꢀ
Tach
Blackꢀ
Arm
Whiteꢀ
Arm
J11
Blueꢀ
Tach
Redꢀ
Tach
TEST FOR FEEDBACK VOLTAGE TO
CONTROL BOARD
1. Disconnect the main AC input power to the
machine.
EXPECTED
VOLTAGE
TO LEAD
FROM LEAD
2. Locate plug J4 and the tach leads. See
Figure F.5.
3.0 TO 4.0
VDC
BLUE (+)
Black (-)
3. Connect main input power to the machine.
4. Make the following voltage tests:
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.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
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.
• All input power must be electrically dis-
connected before proceeding.
7. If the leads are okay, the tachometer circuit
may be faulty, replace the tachometer circuit.
a. Turn the machine OFF between each
test.
8. Replace the tool tray.
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.
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F-19
F-19
TROUBLESHOOTING AND REPAIR
OUTPUT BRIDGE RECTIFIER 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 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
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F-20
F-20
TROUBLESHOOTING AND REPAIR
OUTPUT BRIDGE RECTIFIER TEST (continued)
FIGURE F.6 – RECTIFIER TEST POINTS
+
-
Negative Lead
PROCEDURE
1. Remove input power to the Power MIG® 215XT
machine.
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.
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.
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.
NOTE: Do not disassemble the rectifier assembly.
7. Replace the left case side.
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F-21
F-21
TROUBLESHOOTING AND REPAIR
CONTACTOR 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 Contactor is functional.
MATERIALS NEEDED
12 VDC Supply
Volt/Ohmmeter
7/16” Wrench
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F-22
F-22
TROUBLESHOOTING AND REPAIR
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.
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).
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.
8. If the resistance is “high” or “open” between the
two large terminals when the contactor is acti-
vated, the contactor is faulty. Replace.
4. Using the 7/16” wrench, remove one lead from
the contactors large terminals. See Figure F.7.
See the Wiring Diagram.
9. If the contactor activates and the resistance
between the terminals is low when the 12 VDC
is applied, the contactor is good
5. Carefully apply 12 VDC to the contactor coil
leads. (small terminals)
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.
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.
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.
6. If the contactor does not activate when the
12VDC is applied, the contactor is faulty.
Replace.
12. Replace the tool tray.
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F-23
F-23
TROUBLESHOOTING AND REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
(MAX TAP “G”)
0 volts
10.0V
5ms
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
Volts/Div.....................10V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-24
F-24
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”)
0 volts
1.0 ms
20.0V
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
Volts/Div.....................20V/Div.
Horizontal Sweep..1.0 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-25
F-25
TROUBLESHOOTING AND REPAIR
ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
(MAX TAP “G”)
ONE OUTPUT DIODE NOT FUNCTIONING
0 volts
5ms
20.0 V
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
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-26
F-26
TROUBLESHOOTING AND REPAIR
ABNORMAL OPEN CIRCUIT VOLTAGE
OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”)
0 volts
5ms
20.0 V
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
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-27
F-27
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE
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
The following procedure will aid the technician in removing the Control Board for
replacement.
MATERIALS NEEDED
5/16” Nutdriver
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F-28
F-28
TROUBLESHOOTING AND REPAIR
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.
6. Carefully remove the control board.
2. Using a 5/16” nutdriver, remove the three
screws securing the tool tray.
7. Mount the new board to the nylon mounting
pins.
3. Locate the control board.
8. Reconnect any plugs or leads previously
removed.
4. Disconnect all associated plugs and leads con-
nected to the control board.
9. Replace the tool tray previously removed.
5. Depress the retaining pins on the sides of the
four nylon mounts to release the control board.
See Figure F.8.
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F-29
F-29
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE
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
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
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F-30
F-30
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE
(continued)
FIGURE F.9 – WIRE DRIVE LOCATION
Wire Drive
PROCEDURE
1. Remove power to the machine.
5. Using a 5/16” nutdriver, remove the three
mounting screws next to the wire drive assem-
2. Lift cover to gain access to the wire drive. See
Figure F.9.
6. Using a 5/16” nutdriver, remove the two screws
3. Using a pair of pliers, disconnect the gas hose
7. Carefully maneuver the wire drive assembly out
the side of the machine to gain access to plug
J4. See Wiring Diagram.
4. Using a 9/16” nut driver, remove the thick black
positive lead located just above the gas hose.
8. Disconnect plug J4.
NOTE: Disconnect lead from the wire drive motor
assembly, not the machine.
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F-31
F-31
TROUBLESHOOTING AND REPAIR
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
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F-32
F-32
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE
(continued)
1. Place the new wire drive assembly into its prop-
er position.
5. Using a 3/4” nut driver, replace the thick black
lead previously removed.
2. Connect plug J4.
6. Reconnect the gas hose to the wire drive
assembly.
3. Maneuver assembly back into its original posi-
tion.
7. Close case wrap around cover.
4. Replace all mounting screws previously
removed.
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F-33
F-33
TROUBLESHOOTING AND REPAIR
OUTPUT DIODE BRIDGE RECTIFIER
REMOVAL AND REPLACEMENT PROCEDURE
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
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
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F-34
F-34
TROUBLESHOOTING AND REPAIR
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.
7. Using a 1/2” nutdriver remove the three bolts
mounting the bracket to the rectifier. The recti-
2. Locate the output diode bridge rectifier. See
Figure F.12.
8. Mount the new rectifier to the mounting bracket
using the three 1/2” bolts.
3. Using a 1/2” nutdriver label and remove the four
thick black leads connected to the rectifier.
9. Carefully manipulate the rectifier and mounting
bracket as a one back into the machine to its
proper location.
NOTE: Be sure to label lead terminals also.
Take note of washer placement upon
removal.
10. Mount the unit to the bottom of the machine
using the four 5/16” mounting bolts previously
removed.
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
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.
6. Carefully manipulate the output diode bridge
rectifier and the mounting bracket out of the left
side of the machine.
13. Replace the left side of the case wraparound
cover.
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F-35
F-35
TROUBLESHOOTING AND REPAIR
OUTPUT DIODE BRIDGE RECTIFIER
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.13 – OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET
5/16" Mounting
Bracket Mounting
Bolts
1/2" Rectifier
Mounting Bolts
Mounting
Bracket
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F-36
F-36
NOTES
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F-37
F-37
TROUBLESHOOTING AND REPAIR
OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE
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
The following procedure will aid the technician in removing the Output Capacitors for
repair or replacement.
MATERIALS NEEDED
3/8” Nutdriver
1/2” Wrench
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F-38
F-38
TROUBLESHOOTING AND REPAIR
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.
5. Remove the capacitor bank assembly from the
machine.
2. Locate capacitor bank. See Figure F.14.
6. Place the new capacitor bank into its proper
location inside the machine.
3. Label and remove the five leads connected to
the capacitor bank using a 1/2” wrench. Note
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.
4. Using a 3/8” nutdriver, remove the three capac-
itor bank nuts and lock washers from the three
9. Replace the lower right side case wraparound
cover previously removed.
Power MIG® 215XT
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F-40
F-40
NOTES
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F-41
F-41
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE
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
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
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F-42
F-42
TROUBLESHOOTING AND REPAIR
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.
7. Using a 1/2” nutdriver, label and remove lead
X1 from the output diode bridge rectifier.
2. Using a 5/16” nutdriver, remove the tool tray.
3. Locate the main transformer. See Figure F.16.
8. Using a 5/16” Nutdriver, open the rear access
9. Disconnect lead 118 from the rear access
4. Label and disconnect leads X9, X10, 104B, &
10. Feed lead 118 toward the inside of the
machine.
5. Using a flathead screwdriver, Label and discon-
nect lead H1B and other associated lead con-
nected to the same terminal. These leads are
11. Cut any necessary cable ties.
12. Remove any necessary wiring harnesses.
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
14. Using a 1/2” nutdriver, remove the four main
transformer mounting bolts and associated
washers. See Figure F.16.
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F-43
F-43
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE
(continued)
FIGURE F.17 – LEADS X9, X10, 104B, 104C, & H1B
104B
104C
X9
X10
H1B
15. Carefully maneuver the main transformer out
the left side of the machine.
5. Reconnect lead X1 to the output diode bridge
rectifier.
NOTE: Two people may be needed to maneuver
the main transformer out of the machine.
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.
REPLACEMENT
1. Carefully maneuver the new main transformer
back into the machine and onto its mounting
studs.
8. Replace any necessary cable ties and wiring
harnesses.
2. Using a 1/2” nutdriver, mount the main trans-
former in its proper position.
9. Reconnect leads X9, X10, 104B, & 104C. See
Wiring Diagram.
3. Reconnect leads 118 and 121 previously
removed.
10. Using a 5/16” nutdriver, replace the tool tray.
11. Using a 3/8” nutdriver, replace both sides of the
case wraparound cover.
4. Using a 5/16” nutdriver, close the rear access
panel previously opened.
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F-45
F-45
TROUBLESHOOTING AND REPAIR
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
4
L2
208V
L1
230V
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F-46
F-46
NOTES
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F-47
F-47
TROUBLESHOOTING AND REPAIR
FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE
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
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
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F-48
F-48
TROUBLESHOOTING AND REPAIR
FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE
(continued)
FIGURE F.22 – FAN MOUNTING BOLTS
REAR
Fan
Blade
Fan
Motor
Fan
Mounting
Band
11/32"
Mounting
Nuts
5/16" Bolts
PROCEDURE
1. Using a 3/8” nutdriver, remove the lower right
side of the case wraparound cover.
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.
3. Using a 5/16” nutdriver, remove the four fan
mounting screws from the rear of the machine.
See Figure F.22.
11. Replace the two 11/32” fan motor mounting
nuts and lockwashers.
4. Using an open end 11/32” wrench, remove the
two fan motor mounting nuts and lockwashers.
See Figure F.22.
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.
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.
14. Replace the lower right case cover.
7. Carefully maneuver the fan motor and fan blade
out of the right side of the machine.
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F-49
F-49
TROUBLESHOOTING AND REPAIR
OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE
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
The following procedure will aid the technician in removing the Output Contactor for
repair or replacement.
MATERIALS NEEDED
7/16” Wrench
5/16” Nutdriver
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F-50
F-50
TROUBLESHOOTING AND REPAIR
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.
7. Replace output contactor.
8. Using a 7/16” wrench, mount the new output
contactor in its proper location.
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.
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.
4. Remove lead 107A and note lead placement.
See Figure F.23.
11. Replace the tool tray using a 5/16” nutdriver.
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-
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F-52
F-52
TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR
INPUT IDLE AMPS AND WATTS
Input Volts/Herts
230/60
Maximum Idle Amps
2.0
Maximum Idle Watts
150
OPEN CIRCUIT VOLTAGE
35 - 40 VDC
WIRE SPEED RANGE
50 - 700 IPM (1.27 - 17.8 m/minute)
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
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 – ControlꢀPC Board * – (G4414-2 PG1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Schematic – ControlꢀPC Board – (G4414-2 PG2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
Schematic – ControlꢀPC 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.
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G-2
G-2
ElEcTrical DiaGramS
WiriNG DiaGram - cOmplETE machiNE - l12184-1
POWER MIG 215XT (208/220/230V)
FOR CODE 11521
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
COLOR CODE
NOTES:
N.A.
WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF
IMMEDIATE AND FUTURE APPLICATIONS.
C
AVITY NUMBERING SEQUENCE
OARD)
N.B.
THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIVE”. TO CHANGE POLARITY, TURN
THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK
STUD.
(COMPONENT SIDE OF P.C.
B
B
-
BLACK
WHITE
RED
W -
R -
U -
CONTROL BOARD
1
8
1
3
6
1
2
BLUE
J1
J2
J3
1
2
1101A
16
9
4
INDICATES CONNECTOR CAVITY No.
** CAVITY
1102A
1103A
RECTIFIER
ASSEMBLY
THERMOSTAT
TRANSFORMER
THERMOSTAT
3
1104A
1104B
1104C
1104A
1105A
1106A
4
5
6
7
8
NUMBERING SEQUENCE
(NON-LEAD SIDE OF CONNECTOR)
J4 (TRIGGER,
T
ACHOMETER,
MO
T
OR SIDE)
4
1107A
1108A
1
1
3
6
PA
J1
1103A
R2
4
5
8
9
1109A
1110A
1111A
10
11
12
13
1109A
1113A
IR
W
E
FEED
1112A
1113A
SPEED
1114A
1115A
1116A
14
15
1108A
16
PA **
3
4
5
6
J5
1116A
1
2
1
1116B
1104C
1105A
1106C
GAS
SOLENOID
2
1110A
1114A
X10
3
4
5
6
1122
1116B
27.8V
1106
C
1107A
1106A
1104D
1105B
SINGLE PHASE
BRIDGE
S
SHOWN IN
WITCH AND GUN TRIGGER
M
1121
X9
M
AGNU
100 L PUSH
1121
1122
1118A
RECTIFIER
GUN MODE.
100SG READY
X8
X7
X6
X5
X4
X3
X2
X1
G
F
1124
GUN
1123
TRIGGER
J6
SWITCH
H1
1124
1
L2
L1
1
1
1118
324
325
327
326
E
D
C
B
A
2
3
1111A
1117
2
3
2
3
J2
H3
H4
H2
L1
L2
1117A
1123
4
5
6
TORROID
T
O
S
INGLE PHASE
1104D
4
4
CONTACTOR
SUPPLY LINE
J4
H2
220
230
208V
V
H1
H4
1
**
1115A
W
2
3
4
TAP SELEC
SW TCH
TOR
B
I
R
U
B
H1
RECONNECT
ANEL
H3
P
1101A
1102A
L
INE
SW TCH
S1
I
5
6
7
8
G
P
OWER
TRANSFORMER
X11
X12
1
2
115V
J3
T
O
GROUND PER
IONAL ELECTRICAL
CODE
1112A
1105B
NA
T
B
W
B
15A
D
+
401A
401
403
MOTOR
/
P.M.
X11
GEAR OX
B
T
A
C
H
D
U
B
-
FAN
115V
MOTOR
TO
ORK
W
W
X12
402A
402
40 OHMS
50 W
C1
C2
+
C1 AND C
31,000 MFD
50V
2
+
OUTPU
CHOK
T
E
R.F. FILTER
B
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.
pOWErꢀmiG® 215XT
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G-3
G-3
Enhanced Diagram
ElEcTrical DiaGramS
SchEmaTic - cOmplETE machiNE - l12308-1 pG1
1 - 8 0 3 2 L 1
CHANGE DETAIL: REVISED PAGE 2.
ENGINEERING CONTROL
LED
MANUFACTURER: No
FRONT
TOP
LEFT
ONLY ON
FR
FR
+39.25VDC
COM
CONTACTOR
O
O
M
M
X
X9
10
10J1
14J1
CONTROL
P.C. OARD
EARLY CODES
B
(SCHEMATIC G4414)
6J1
14J1
7J1
1106A
1114A
1107A
CONTROLS THE
FUNCTIONALITY OF
THE MACHINE
40 VDC
R2
10K
POT
LOCATED ON
CASE FRONT
3J1
13J1
9J1
1103A
1113A
1109A
LOCATED INSIDE OF P.C.
BOARD COMPARTMENT
ADJUSTS WIRE
FEED SPEED
1106A X9 1114A
RECTIFIER
DIODE
BRIDGE
(TOPLEFT FRONT OF WELDER)
GAS SOLENOID
COM
OPEN = 36.5VDC
1108A
1116A
8J1
16J1
SPOOL GUN
DETECT SIGNAL
12V
20 OHM COIL
6VHOLD
SOLENOI
D
-
MOVED
TO CON
TRO
L
LOCATED
ON RIGHT
CASE BACK
BOARD ON CODE 1109
AND HIGHER
9
LOCATED IN P.C. BOARD
COMPARTMENT
LOCATED ON
TRANSFORMER
BAFFLE
MAGNUM 100SG ADAPTER PANEL
X10
6J14
16J14
12J14
LOCATED IN
MAGNUM 100SG
READY ADAPTER
PANEL NEXT TO
WI RE DRI VE.
1105A
1105B
6J5
3J5
2J14
MOTOR USE
14J14
1106B
100 SG
1J3
2J3
SOLENOID/SPOOL
GUN DETECT USE
1116B
1J5
5J5
4J5
2J5
SPOOL GUN
FOR ADDITIONAL
SPOOL GUN OPTIONS/
ADAPTER PANEL
CONNECTIONS
DETECT
1104D
1106C
1104C
6J2
5J2
3J2
2J2
1J2
4J2
GUN TRIGGER
USE
1123
1121
1122
1118A
(SEEPAGE2)
SHOWS MAGNUM
PUSH GUN
INSTALLED
FRONT OF DRIVE
ROLL AREA
1124
1117A
1124
LOCATED ON
MAIN
TRANSFORMER
WINDINGS
LOCATED ON
INPUT
RECTIFIER
1123
LOCATED INSIDE
OF P.C. BOARD
TRIGGER COMPARTMENT
SWITCH SHOWN IN MAGNUM
100 PUSH GUN POSITION
G
UN
1104A
4J1
1104B
N.C.
1
324
325
326
327
4J6
N.C.
11J1
2J6
1J6
1111A
2
3
6J1
1118A
1117A
1118
1117
CONTROL
BOARD
POWER
14J1
4
3J6
TOROID
(1 TURN)
10J1
100 SG SPOOL
GUN MOTOR
USE
ON CODE 11099 AND HIGHER
LOCATED INSIDE OF
P.C. BOARD COMPARTMENT
MOT
O
O
R +
R -
W
B
8J4
7J4
5J1
12J1
1105A
1112A
MOT
B
W
LOCATED ON FRONT
OF MACHINE'SBASE
TOROID
(1 TURN)
MOTOR / GEARBOX
TACH
OHMS = 1.5 TO 6.5
1.8 VDC @50 IN/MIN
26.5 VDC @700 IN/MIN
5VDC
T
T
ACH SUPPL
ACH SIGNAL
ACH COM
Y
MAIN
TRANSFORME
R
U
B
R
U
B
3J4
4J4
5J4
15J1
1J1
2J1
1115A
1101A
1102A
R
T
B
B
T
O R
O U
=
=
5
T
O
6V @ ANY SPEED
X10
TOROID
(1 TURN)
T
3.5V @ ANY SPEED
LOCATED INSIDE
OFP.C. BOARD
COMPARTMENT
27.8V
1107
A
LOCATED ON
MACHINE'S BASE
P.C. BOARD
COMPARTMENT SIDE
X9
X8
X7
S
INGLE PHASE
LOCATED ON BASE IN
THE MIDDLE OF THE
MACHINE
0V N
O
TRIGGER
IGGER
25.6VAC
23.2VAC
20.9VAC
BRIDG
E
R
LOCATED ON
CASE BACK
G
F
LOCATED INSIDE
OF P.C. BOARD
COMPARTMENT
OHMS = 10
RECTIFIE
8.6V
TR
LOCATED ON MACHINE'S
BASE, TOWARDS BACK,
WI RE DRI VE SI DE
OUTPUT
CHOKE
H1
L2
L1
X6
X5
X4
X3
X2
X1
E
D
C
B
A
+
H2
H3
H4
L1
L2
T
T
T
T
T
T
T
AP
AP
AP
G
= 36.0VDC
18.7VAC
16.4VAC
MOTOR
EARBOX
TO
S
INGLE PHASE
F
E
=
32.8VDC
CONTACTOR
G
SUPPLY INE
L
= 29.6VDC
H2
(NORMALLY OPEN)
22
0
0
208V
V
23
H1
H4
AP D
AP C
=
=
26.5VDC
23.2VDC
14.1VAC
12.0VAC
RATED @ 300A
R1
W
31000/50
AP
AP
B
A
= 20.0VDC
= 16.9VDC
TAP SELECTOR SWITCH
B
BANK OF TWO
CAPACITORS
H1
RECONNECT
PANEL
H3
TO
WORK
LINE
SWITCH
S1
FRONT LEFT
LOCATED ON
MACHINE'S
LEFT REAR
LOCATED ON
MACHINE'S FRONT
LEFT MIDWAY
-
G
RIGHT REAR
NEAR FAN
MOLDED
TO GROUND PER
NATIONAL ELECTRICAL
CODE
LOCATED ON
BOTTOM SIDE OF
OUTPUT STUD
OUTPUT
401A
STUDS
X11
115V
401
402
LOCATED ON BASE OF
FEEDER COMPARTMENT
R.F. FILTER
X12
15A
402A
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
P
ON
E
NT
V
ALUE
UNITS:
LE
A
D
COLOR CODE:
403
CAVITY NUMBERING SEQUENCE
FAN
CIRCUIT
(COMPONENT SIDE OF P.C. BOARD)
B-BLACK
G-GREEN
O-ORANG
R-RE
U-BLU
W- HIT
Y-YELLO
MOTOR
BREAKER
VOLTS
LOCATED ON
CASE BACK
WITH REAR
TO FRONT
AIRFLOW
LOCATED ON
CASE BACK
115V
E
1
8
3
6
1
X12
F
AN IS CON
ON WHEN P
SWITCH IS ON
T
O
INUOUSL
WER
Y
1
J1
,
D
J2
J3
J14
CONNECTOR PIN NUMBERS:
E
16
9
4
2
W
E
EX.
12
PIN CONNECTOR
W
(
NON-LEAD SIDE OF CONNECTOR)
J4
2
1
7
6
(TRIGGER,
LABELS:
T
ACHOMETER
,
MOTOR
S
IDE)
4
COMMON
FRAM ROUND
EARTH GROUND
12
LATC
1
1
3
6
E
G
H
PA
VIEW O
F
CONNECTOR ON PC BOARD
4
5
8
PROPRIE
TARY &
T
TO OTHER PA
HIS DOCUME
N
T CONTAINS P
USE
R
OPRIETARY INFORMATIO
U
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
W
N
D MAY NOT BE
D
OLN GLOBAL, INC.
UPLICATED,
C
OMMUNICATED
R
TIES O
R
D
FOR ANY P
RPOSE WITHOUT THE EXPRESS
RITTEN PERMISSIO
N
OF LIN
C
CO FIDENTIAL:
N
MANUFACTURIN
NLESS OTHERWISE SPE
N 2 PLACE DECIMALS IS
ON LA DECIMALS IS
N ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE ( ") TO A REE
G
TOLERANCE PER E2056
IFIE TOLERA CE
.02 in. ( 0.5 mm)
.002 n. 0.05 mm)
SCALE:
NONE
CONTROL:
CLEVELAND
U
O
C
D
N
:
EQUIPMENT TYPE
SUBJECT:
:
_1__
2
POWER MIG 216
MACHIN SCHEMATI
PAGE
OF ___
±
±
DR
NGINEER:
APPROVED:
A
WN BY:
cstuble
T. SPEAR
OBS
3
P
C
E
±
i
(±
IF PRINTED
DOCUMENT
DOCUMENT
REVIS ON:
O
±
@
A2 SIZE
NUMBER:
I
E
C
E
"
G
t
UNITS:
WITH PUBLISHED STANDARDS.
REFERENCE:
APPROVAL
DATE:
MATERIAL
UF
PROJECT
NUMBER:
L12308-1
4/9/2010
C
CRM41566
INCH
DISPOSITION:
L12308
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWErꢀmiG® 215XT
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ElEcTrical DiaGramS
SchEmaTic - cOmplETE machiNE - l12308-1 pG2
1 - 8 0 3 2 L 1
CHANGE DETAIL: REVISED PAGE 2.
ENGINEERING CONTROLLED
MANUFACTURER: No
CONTROLS THE
FUNCTIONALITY OF THE SSTANDARD FEED MOTOR CIRCUIT
PTC
CONTROL
P.C. OARD
(SCHEMATIC G4414)
B
THE MACHINE
ALSO IS USED FOR ALL THE SPOOL GUN
MOTORS WHEN SELECTED WITH
ADAPTER PANEL.
FROM STANDARD
GUN TRIGGER
11J1
12J1
5J1
SENSING FOR 7-PIN
SPOOL GUN TO
OPERATE
REMOTE WFS
FOR 7-PIN
SPOOL GUN
REMOTE WFS
FOR 6-PIN
SPOOL GUN
FROM 112A FEED
MOTOR NEG LEAD
SPOOL GUN
GAS SOLENOID
.05
LOCATED ON
CASE BACK
V=8.7VDC WHEN GAS IS FLOWING
COIL: 21.6 OHMS, 12VDC COIL
SPOOL
GUN
MOTOR
G
AS SOLENOID -
TOROI
D
GAS SOLENOID +
2.2VDC @50 IN/MIN
20VDC @700IN/MIN
6-PIN
AMPHENOL
K2703-1 SPOOL GUN
ADAPTER PANEL
P.M.
M
OT
O
R +
A
B
MAX
MOT
OR -
LOCATED ON
WFS
100K POT
DIVIDER PANEL
INWIREDRIVE
COMPARTMENT
C
D
E
F
SPOOL GUN POT
MOTOR + SPEED CONTROL
FROM CONTROL BOARD
+
S2
(TOSWITCHBETWEEN
SPOOL GUN AND
STANDARD GUN)
TOGGLE
SWITCH
+
**
TO STANDARD FEED MOTOR
3J5
6J5
1J5
5J5
4J5
2J5
3PB
6PB
1PB
5PB
4PB
2PB
105C
105D
116C
104F
106D
104E
105E
SPOOL GUN TRIGGER
16J1 - POWER TO STANDARD GAS SOLENOID AND USED
FOR SPOOL GUN DETECT (AT CONTROL BOARD)
CLOSING GUN TRIGGER MAKES BOTH
THE STANDARD GUN AND THE SPOOL
GUNS ELECTRICALLY HOT!
104G
FROM STANDARD GUN TRIGGER
+40FROMDIODEDRIDGE
NORMALLY CLOSED (SHOWN
INSPOOL GUNPOSITION)
S3
4J1 - TO CONTROL BOARD (TRIGGER)
SPOOL GUN
SELECTOR
SWITCH
THERMOSTAT
AL
PAGE
SPOOL GUN
TRIGGER
COMMON
7-PIN
AMPHENOL
SPOOL GUN TRIGGER
S
O
SEE
1
F
E
SPOOL GUN
MOTOR
COMMON
MOTOR -
B
C
MAX
WFS
5K POT
D
G
SPOOL
GUN
MOTOR
P.M.
SPOOL GUN POT
1.7VDC @50 IN/MIN
24VDC @700IN/MIN
MOTOR +
105G
A
1 TOROI
D
ON
B
OTH LEADS
FOR M
SPOOL GUNS
A
GNUM
S
G
AND M
PERATION, REMOVE
MAGNUM 100SG ADAPT PANEL (AND
HARNESS SWITCH) FROM P5 OF MA HINE
OOL GUN
AGNUM 250LX
R
EF
ADAPT
INSTR
E
R TO L11543-1 FOR SPOOL GUN
PANEL INSTALLATIO
CTIONS.
O
**
E
U
R
N
ER
/
C
HARNESS AN
D
PLUG
I
N
K2703-1 SP
HARNESS
COM
CAPACITOR: MFD/
RESISTOR: OHMS/WATTS
P
ON
E
NT
V
ALUE
UNITS:
LE
A
D
COLO
R
CODE:
E
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
B-BLACK
G-GREEN
O-ORANG
R-RE
U-BLU
W- HIT
Y-YELLO
VOLTS
1
8
1
1
3
6
J1
,
D
J2
J3
J1
4
CONNECTOR PIN NUMBERS:
E
16
9
4
2
W
E
W
EX.
12
PIN CONNECTOR
(
NON-LEAD SIDE OF CONNECTOR)
J4
2
1
7
6
(TRIGGER,
LABELS:
T
ACHOMETER
,
MOTOR
S
IDE)
4
COMMON
FRAM ROUND
EARTH GROUND
12
LATC
1
1
3
6
E
G
H
PA
VIEW O
F
CONNECTOR ON PC BOARD
4
5
8
PROPRIETARY &
T
TO OTHER PA
HIS DOCUME
N
T CONTAINS P
USE
R
OPRIETARY INFORMATIO
U
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
W
N
D MAY NOT BE
D
UPLICATED,
OLN GLOBAL, INC.
C
OMMUNICATED
R
TIES O
R
D
FOR ANY P
RPOSE WITHOUT THE EXPRESS
RITTEN PERMISSIO
N
OF LIN
C
CONFIDENTIAL:
MANUFACTURIN
NLESS OTHERWISE SPE
N 2 PLACE DECIMALS IS
ON LA DECIMALS IS
N ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE ( ") TO A REE
G
TOLERANCE PER E2056
IFIE TOLERA CE
.02 in. ( 0.5 mm)
.002 n. 0.05 mm)
SCALE:
NONE
CONTROL:
CLEVELAND
U
O
C
D
N
:
EQUIPMENT TYPE
SUBJECT:
:
_2__
2
POWER MIG 216
MACHIN SCHEMATI
PAGE
OF ___
±
±
DR
NGINEER:
APPROVED:
A
WN BY:
cstuble
T. SPEAR
OBS
3
P
CE
±
i
(±
IF PRINTED
DOCUMENT
DOCUMENT
REVIS ON:
O
±
@
A2 SIZE
NUMBER:
I
E
C
E
"
G
t
UNITS:
WITH PUBLISHED STANDARDS.
REFERENCE:
APPROVAL
DATE:
MATERIAL
UF
PROJECT
NUMBER:
L12308-1
4/9/2010
C
CRM41566
INCH
DISPOSITION:
L12308
DO NOT SCALE THIS
DRAWING
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWErꢀmiG® 215XT
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ElEcTrical DiaGramS
SchEmaTic - cONTrOl bD - G4414 pG1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWErꢀmiG® 215XT
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ElEcTrical DiaGramS
SchEmaTic - cONTrOl bD - G4414 pG2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWErꢀmiG® 215XT
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ElEcTrical DiaGramS
SchEmaTic - cONTrOl bD - G4414 pG3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWErꢀmiG® 215XT
Download from Www.Somanuals.com. All Manuals Search And Download.
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