SVM167-A
January, 2011
Ā®
POWER MIG 215
For use with machines having Code Numbers:
11070, 11099, 11247
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
SERVICEź¢MANUAL
Copyright Ā© Lincoln Global Inc.
ā¢ World's Leader in Welding and Cutting Products ā¢
ā¢ Sales and Service through Subsidiaries and Distributors Worldwide ā¢
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBź¢SITE: 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 āhotā when the welder is on.
Do not touch these āhotā 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
ā¢ Semiautomatic DC Constant Voltage (Wire) Welder.
ā¢ DC Manual (Stick) Welder.
ā¢ 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 āhotā.
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 āhotā 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 manufacturerās instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerās safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
POWER MIGĀ® 215
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iii
iii
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 āSafety in Welding and Cuttingā (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
ā¢Away from areas where they may be struck or subjected to
physical damage.
ā¢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 āhotā 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 ācleanedā. For information, purchase āRecommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substancesā, 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,
āPrecautions for Safe Handling of Compressed Gases in
Cylinders,ā 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 manufacturerās
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerās recommendations.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B ā Standard for Fire Prevention
During Welding, Cutting and Other Hot Workā, 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.
POWER MIGĀ® 215
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iv
iv
SAFETY
6. Eloigner les matƩriaux inflammables ou les recouvrir afin de
PRĆCAUTIONS DE SĆRETĆ
prĆ©venir tout risque dāincendie dĆ» aux Ć©tincelles.
Pour votre propre protection lire et observer toutes les instructions
et les prƩcautions de sƻretƩ specifiques qui parraissent dans ce
manuel aussi bien que les prƩcautions de sƻretƩ gƩnƩrales suiv-
antes:
7. Quand on ne soude pas, poser la pince Ć une endroit isolĆ© de
la masse. Un court-circuit accidental peut provoquer un
Ć©chauffement et un risque dāincendie.
8. Sāassurer que la masse est connectĆ©e le plus prĆ©s possible de
la zone de travail quāil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dāautres endroits
ƩloignƩs de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
cĆ¢bles de grue, ou autres circuits. Cela peut provoquer des
risques dāincendie ou dāechauffement des chaines et des
cĆ¢bles jusquāĆ ce quāils se rompent.
SĆ»retĆ© Pour Soudage A LāArc
1. Protegez-vous contre la secousse Ć©lectrique:
a. Les circuits Ć lāĆ©lectrode et Ć la piĆ©ce sont sous tension
quand la machine Ć souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vƩtements mouillƩs. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trĆ©s attention de bien sāisoler 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 couchƩ pour lesquelles une grande
partie du corps peut ĆŖtre en contact avec la masse.
c. Maintenir le porte-Ć©lectrode, la pince de masse, le cĆ¢ble de
soudage et la machine Ć souder en bon et sĆ»r Ć©tat defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliƩrement important pour le soudage de tƓles
galvanisƩes plombƩes, ou cadmiƩes ou tout autre mƩtal qui
produit des fumeƩs toxiques.
10. Ne pas souder en prƩsence de vapeurs de chlore provenant
dāopĆ©rations de dĆ©graissage, nettoyage ou pistolage. La
chaleur ou les rayons de lāarc peuvent rĆ©agir avec les vapeurs
du solvant pour produire du phosgƩne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-Ć©lectrode dans lāeau pour le
refroidir.
e. Ne jamais toucher simultanƩment les parties sous tension
des porte-Ć©lectrodes connectĆ©s Ć deux machines Ć souder
parce que la tension entre les deux pinces peut ĆŖtre le total
de la tension Ć vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sƻretƩ, voir
le code āCode for safety in welding and cuttingā CSA Standard
W 117.2-1974.
f. Si on utilise la machine Ć souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-Ć©lectrode sāapplicuent aussi au pistolet de
soudage.
PRĆCAUTIONS DE SĆRETĆ POUR
LES MACHINES Ć SOUDER Ć
TRANSFORMATEUR ET Ć
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protƩger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le cĆ¢ble-Ć©lectrode autour de nāimporte quelle partie du
corps.
3. Un coup dāarc peut ĆŖtre plus sĆ©vĆØre quāun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant appropriƩ ainsi
quāun verre blanc afin de se protĆ©ger les yeux du rayon-
nement de lāarc et des projections quand on soude ou
quand on regarde lāarc.
1. Relier Ć la terre le chassis du poste conformement au code de
lāĆ©lectricitĆ© et aux recommendations du fabricant. Le dispositif
de montage ou la piece Ć souder doit ĆŖtre branchĆ© Ć une
bonne mise Ć la terre.
b. Porter des vĆŖtements convenables afin de protĆ©ger la peau
de soudeur et des aides contre le rayonnement de lāarc.
c. ProtĆ©ger lāautre personnel travaillant Ć proximitĆ© au
soudage Ć lāaide dāĆ©crans appropriĆ©s et non-inflammables.
2. Autant que possible, Iāinstallation et lāentretien du poste seront
effectuƩs par un Ʃlectricien qualifiƩ.
3. Avant de faires des travaux Ć lāinterieur de poste, la debranch-
er Ć lāinterrupteur Ć la boite de fusibles.
4. Des gouttes de laitier en fusion sont Ć©mises de lāarc de
soudage. Se protĆ©ger avec des vĆŖtements de protection libres
de lāhuile, tels que les gants en cuir, chemise Ć©paisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sĆ»retĆ© Ć leur place.
5. Toujours porter des lunettes de sƩcuritƩ dans la zone de
soudage. Utiliser des lunettes avec Ć©crans lateraux dans les
zones oĆ¹ lāon pique le laitier.
POWER MIGĀ® 215
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v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
i-iv
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
P202-H.2
POWER MIGĀ® 215
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Section A
Section A
TABLE OF CONTENTS
- INSTALLATION SECTIONź¢-
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-2
POWER MIGĀ® 215
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A-2
A-2
INSTALLATION
TECHNICAL SPECIFICATIONS ā POWER MIGĀ® 215
INPUT ā SINGLE PHASE ONLY
Standard Voltage/Phase/Frequency
208/230/1/50/60 Hz
Input Current @ 170 Amp Rated Output Input Current @ 215 Amp Rated Output
(With 115V receptacle loaded to 15A)
39/35 Amps
(With 115V receptacle loaded to 15A)
45/41 Amps
RATED OUTPUT
Duty Cycle
30%
40%
Amps
Volts at Rated Amperes
22 Volts
23 Volts
215 Amps
190 Amps
170 Amps
60%
24 Volts
OUTPUT
Welding Current Range
30 ā 250Amps
Maximum Open Circuit Voltage
35 Volts
Welding Voltage Range
13.5-24 Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES
75Ā°C Copper Wire
75Ā°C Copper Wire
in Conduit
AWG (IEC) Sizes
(For lengths
exceeding 100 ft.)
Input Ampere
Rating On
in Conduit
AWG (IEC) Sizes
(For lengths
Input Voltage/
Fuse or Breaker
Size (Super Lag)
Frequency (Hz)
Nameplate
up to 100 ft.)
2
2
208/50/60
230/50/60
60
60
45A
41A
10 (6 mm )
2
8 (10 mm )
8 (10 mm )
2
10 (6 mm )
NOTE: Use #10 AWGź¢Grounding Wire
WIRE SPEED RANGE
Wire Speed
50 ā 700 IPM (1.27 ā 17.8 m/minute)
PHYSICAL DIMENSIONS
Width
18.88 in
480 mm
Height
31.79 in
808 mm
Depth
38.78 in
985 mm
Weight
210 Ibs
95 kg
TEMPERATURE RANGES
STORAGE TEMPERATURE RANGE
-40Ā°F to 185Ā°F(-40Ā°C to +40Ā°C)
OPERATING TEMPERATURE RANGE
-4Ā°F to 104Ā°F(-20Ā°C to +40Ā°C)
POWER MIGĀ® 215
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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.
ā¢ Do not touch electrically live parts such as
output terminals or internal wiring.
ā¢ Only qualified personnel should perform
this installation.
ā¢ All input power must be electrically dis-
connected before proceeding.
ā¢ Only personnel that have read and under-
stood the POWER MIGĀ® 215 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.
ā¢ Machine must be grounded per any
national, local or other applicable electri-
cal codes.
ā¢ The POWER MIGĀ® power switch is to be
in the OFF position when installing work
cable and gun and when connecting other
equipment.
UNCRATING THE POWER MIGĀ® 215
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
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
LOCATION
Make certain that the input power is electrically
disconnected before removing the screw on the
reconnect panel access cover.
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.
POWER MIGĀ® 215
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A-4
A-4
INSTALLATION
FIGURE A.1 ā Dual Voltage Machine Input Connections
3. The 208/230 volt 50/60 Hz model POWER MIGĀ® 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 āTechnical
proper wire sizes. For long runs over 100 feet, larg-
er copper wires should be used. Fuse the two hot
lines with super lag type fuses as shown in the fol-
lowing 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 inserted into a
grounded receptacle.
If negative (ā) 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 (ā) 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 ā 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.
POWER MIGĀ® 215
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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 MIGĀ® 215 is factory installed with a liner for
.035-.045" (0.9-1.2 mm) electrode and an .035" (0.9
mm) contact tip. Be sure that the contact tip, liner, and
drive rolls all match the size of the wire being used.
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 ācrackingā 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 cylin-
der valve. If adapter is equipped with a plas-
tic washer, be sure it is seated for connec-
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.
tion 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 MIGĀ® 215 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 regula-
tor adjusting knob counterclockwise until the adjust-
ing spring pressure is released.
A gas flow regulator, for Argon blend gas, and an inlet
gas hose are factory provided with the POWER MIGĀ®
215. When using 100% CO an additional adapter will
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.
2
be required to connect the regulator to the gas bottle.
WARNING
WARNING
Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
stand to one side.
CYLINDER may explode if
damaged.
ā¢ 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, āSafety in
Welding and Cuttingā 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:
AUXILIARYź¢POWERź¢RECEPTACLES
(15 Amp 120ź¢Volt Receptacle) The receptacles are UL
and CSAź¢approved.
1. Set gas cylinder on rear platform of POWER MIGĀ®
215. Hook chain in place to secure cylinder to rear
of welder.
POWER MIGĀ® 215
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A-6
A-6
NOTES
POWER MIGĀ® 215
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Section B
Section B
TABLE OF CONTENTS
- OPERATION SECTIONź¢-
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Welding Capability.................................................................................................B-3
Wire Reel Loading.................................................................................................B-4
To Start the Welder................................................................................................B-4
Avoiding Wire Feeding Problems..........................................................................B-7
Wire Feed Overload Protection.............................................................................B-7
POWER MIGĀ® 215
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B-2
B-2
OPERATION
Read entire Operation section before
operating the POWER MIGĀ® 215.
WARNING
ELECTRIC SHOCK can kill.
ā¢ Do not touch electrically live parts
or electrode with skin or wet cloth-
ing. Insulate yourself from work
and ground.
ā¢ Always wear dry insulating
gloves.
FUMES AND GASES can be
dangerous.
ā¢ Keep your head out of fumes.
ā¢ Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS can cause
fire or explosion.
ā¢ Keep flammable material away.
ā¢ Do not weld on closed containers.
ARC RAYS can burn eyes and
skin.
ā¢ Wear eye, ear and body protec-
tion.
Observe all safety information throughout
this manual.
POWER MIGĀ® 215
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B-3
B-3
OPERATION
PRODUCT DESCRIPTION
LIMITATIONS
The output voltage/current of the POWER MIGĀ® 215 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 accommodate a signifi-
cant drift in input power.
The POWER MIGĀ® 215 is a complete semiautomatic
DC voltage arc welding machine built to meet NEMA
specifications. It combines a tapped transformer volt-
age power source with a constant speed wire feeder to
form a reliable robust performance welding system. A
simple control scheme, consisting of continuous full
range wire feed speed control, and 7 output voltage tap
selections provides versatility with ease of use and
accuracy.
DESCRIPTION OF CONTROLS
See Figure B.1
1. Power ON/OFF Switch ā Place the lever in the
"ON" position to energize the POWER MIGĀ® 215.
2. Voltage Control ā 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 proce-
dure decal on the inside of the wire compartment
door.
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.
3. Wire Speed Control ā This controls the wire feed
speed from 50 ā 700 inches per minute (1.2 ā 17.8
m/min). Wire speed is not affected when changes
are made in the voltage control.
Optional Spool Gun and Adapter kit, Dual Cylinder
Mounting kit and Aluminum Feeding Kit for push feed-
ing with standard built in feeder are also available.
FIGURE B.1
RECOMMENDED PROCESSES AND
EQUIPMENT
The POWER MIGĀ® 215 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-
3
Ā®
al adapter) of .025" through .045" (0.6 ā 1.2 mm) solid
steel, .035" (0.9 mm) stainless, 3/64" (1.2 mm) alu-
minum and .035 (0.9 mm), .045" (1.2 mm)
2
1
Ā®
Outershield ; as well as .035" (0.9 mm) and .045" (1.2
Ā®
mm) Innershield self-shielding electrodes.
The POWER MIGĀ® 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.
WIRE DRIVE ROLL
The drive rolls installed with the POWER MIGĀ® 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.
WELDING CAPABILITY
WIRE SIZE CONVERSION PARTS
The POWER MIGĀ® 215 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.
The POWER MIGĀ® 215 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
POWER MIGĀ® 215
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B-4
B-4
OPERATION
6. Position the Readi-Reel so that it will rotate in a direction
PROCEDURE FOR CHANGING
DRIVE ANDź¢IDLE ROLL SETS
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.
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.
8. Lower the Readi-Reel to depress the retaining spring and
align the other inside cage wires with the grooves in the
molded adapter.
9. Slide cage all the way onto the adapter until the retaining
spring "pops up" fully.
3. Remove the outside wire guide retaining plate by
loosening the two large knurled screws.
CAUTION
4. Twist the drive roll retaining mechanism to the
unlocked position as shown below and remove the
drive rolls. (See Figure B.2)
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.
----------------------------------------------------------------------------------------------
FIGURE B.2
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.
LOCKED POSITION
UNLOCKED POSITION
5. Remove the inside wire guide plate.
6. Replace the drive rolls and inside wire guide with a
set marked for the new wire size. NOTE: Be sure
that the gun liner and contact tip are also sized to
match the selected wire size.
7. Manually feed the wire from the wire reel, over the
drive roll groove and through the wire guide and
then into the brass bushing of the gun and cable
assembly.
FIGURE B.1
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).
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.
1
. Open the Wire Drive Compartment Door
WIRE REEL LOADING - READI-REELS,
2. Depress the Release Bar on the Retaining Collar and
remove it from the spindle.
SPOOLS OR COILS
To Mount a 30 Lb. (14 kg) Readi-Reel Package
(Using the Molded Plastic K363-P Readi-Reel
Adapter:)
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.
1. Open the Wire Drive Compartment Door
2. Depress the Release Bar on the Retaining Collar and
remove it from the spindle.
4. Re-install the Retaining Collar. Make sure that the
Release Bar āpops upā and that the collar retainers fully
engage the retaining ring groove on the spindle.
3. Place the Optional Adapter on the spindle
4. Re-install the Retaining Collar. Make sure that the
Release Bar āpops upā and that the collar retainers fully
engage the retaining ring groove on the spindle.
TO START THE WELDER
Turn the āPower Switchā switch to āONā. With the desired voltage
and wire speed selected, operate the gun trigger for welder output
and to energize the wire feed motor.
5. Rotate the spindle and adapter so the retaining spring is
at the 12 o'clock position.
POWER MIGĀ®
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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 pres-
sure arm gives the best welding performance. For best
results, set both pressure arms to the same value.
FEEDING WIRE ELECTRODE
WARNING
When triggering, the electrode and
Set the pressure arm as follows (See Figure B.2a):
drive mechanism are electrically āhotā
relative to work and ground and
remain āhotā several seconds after the
gun trigger is released.
Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6
------------------------------------------------------------------------
NOTE: Check that drive rolls, guide plates and gun
parts are proper for the wire size and type
Accessories section.
Figure B.2a
1. Turn the Readi-Reel or spool until the free end of the
electrode is accessible.
C ORED WIR ES
SOLID WIRES
1
3
5
ALUMINUM
2
4
6
OU TER SHIELD
METALSHIELD
INNERSHIELD
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).
STEEL
STAINLE SS
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.
WIRE DRIVE CONFIGURATION
Changing the Gun Receiver Bushing
WARNING
ELECTRIC SHOCK can kill.
ā¢ Turn the input power OFF at the weld-
ing power source before installation or
changing drive rolls and/or guides.
ā¢ Do not touch electrically live parts.
ā¢ 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.
4. Press gun trigger to feed the electrode wire through
the gun.
IDLE ROLL PRESSURE SETTING
ā¢ Only qualified personnel should perform mainte-
nance work.
WARNING
-----------------------------------------------------------------------
Tools required:
ā¢ 1/4" hex key wrench.
ELECTRIC SHOCK can kill.
ā¢ Turn the input power OFF at the weld-
ing power source before installation or
changing drive rolls and/or guides.
NOTE: Some gun bushings do not require the use
of the thumb screw.
ā¢ Do not touch electrically live parts.
ā¢ 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.
ā¢ Only qualified personnel should perform mainte-
nance work.
------------------------------------------------------------------------
1. Turn power off at the welding power source.
2. Remove the welding wire from the wire drive.
3. Remove the thumb screw from the wire drive.
4. Remove the welding gun from the wire drive.
POWER MIGĀ® 215
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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.
Ā®
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
āArc Welding Safety Precautionsā.
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.
ā¢ When using an open arc process, it
is necessary to use correct eye,
head, and body protection.
10. Tighten the socket head cap screw.
-----------------------------------------------------------------------
11. Insert the welding gun into the gun bushing and
tighten the thumb screw.
6. Position electrode over joint. End of electrode may
be lightly touching the work.
MAKING A WELD
7. Lower welding helmet, close gun trigger, and begin
welding. Hold the gun so the contact tip to work
distance is about 3/8" (10 mm) [3/4" (20 mm) for
1. Check that the electrode polarity is correct for the
process being used, then turn the power switch
ON.
Ā®
Outershield ].
2. Set desired arc voltage tap and wire speed for the
particular electrode wire, material type and thick-
8. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
Ā®
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
POWER MIGĀ® 215
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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
trigger to release gas pressure, and turn off
POWER MIGĀ® 215.
INPUT LINE VOLTAGE VARIATIONS
High Line Voltage ā 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 ā 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 MIGĀ® has solid state overload protection
of the wire drive motor. If the motor becomes over-
loaded, 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 āloop-offsā from coil.
WELDING THERMAL OVERLOAD
PROTECTION
The POWER MIGĀ® 215 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 MIGĀ® 215 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
ā
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
ā
Innershield 5/8" CTWD
.035
.045
.045
NoneReqād NR-211MP
NoneReqād NR-211MP
NoneReqād 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
ā
Contact Tip to Work Distance
* Note- Requires Multiple Pass
**.035 & .045 NR-211 MP are only recommended for a maximum steel thickness of 5/16"
POWER MIGĀ® 215
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B-8
B-8
NOTES
POWER MIGĀ® 215
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C-2
C-2
ACCESSORIES
DRIVE ROLL KITS
ALTERNATIVE MAGNUM GMAW
GUN AND CABLE ASSEMBLIES
Refer to Table C.1 for various drive roll kits that are
available for the POWER MIGĀ® 215.The item in Bold
is supplied standard with the POWER MIGĀ® 215.
The following Magnum 250L gun and cable assemblies
are separately available for use with the POWER
MIGĀ® 215. Each is rated 200 amps 60% 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:
Wire
Size
Drive Roll Kit
.023ā-.030ā (0.6-0.8 mm)
.035ā (0.9 mm)
.045ā (1.2 mm)
KP1696-030S
KP1696-035S
KP1696-045S
Solid
Steel
English Wire
Size
Metric Wire
Size
Length
Part No.
10' (3.0 m)
12' (3.6 m)
15' (4.5 m)
K533-1
K533-2
K533-3
.035ā (0.9 mm)
.045ā (1.2 mm)
KP1697-035C
KP1697-045C
Cored
.035 ā .045"
.025 ā .030"
0.9 ā 1.2 mm
0.6 ā 0.8 mm
10' *3.0 m)
12' (3.6 m)
15' (4.5 m)
K533-4
K533-5
K533-6
Aluminum
3/64ā (1.2 mm)
KP1695-3/64A
TABLE C.1
TABLE C.2
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 MIGĀ® 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.
SPOOL GUN AND ADAPTER KIT
(K1809-1)
The K1809-1includes the Magnum 250SG Spool gun
and the adapter kit for connecting the spool gun to the
POWER MIGĀ® 215.
READI-REEL ADAPTER (K363P)
The K363P Readi-Reel Adapter mounts to the 2" spin-
dle. It is needed to mount the 22-30 lb. Readi-Reels.
The Adapter Kit provides toggle switch selection
between the machineās use with its feeder gun or the
spool gun for same polarity welding with different wire
and gas processes.
DUAL CYLINDER MOUNTING KIT
(K1702-1)
Permits stable side-by-side mounting of two full size
(9" dia. x 5' high) gas cylinders with āno liftā loading.
Simple installation and easy instructions provided.
Includes upper and lower cylinder supports, wheel
axles and mounting hardware.
The kit includes a spool gun adapter module assembly
with a single connecting plug and trigger switch, a rear
gas inlet, fitting hose, solenoid valve assembly, and
mounting hardware with installation and operation
instructions.
SMALL SPOOL SPINDLE ADAPTER
(K468)
WARNING
Remove all input power to the POWER MIGĀ® 215
before installing the Spool Gun and Kit.
The K468 spindle adapter allows the use of 8" diame-
ter small spools.
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C-3
C-3
ACCESSORIES
5. To return to normal POWER MIGĀ® 215 welding,
release the spool gun trigger set spool gun selector
switch to normal and reset feeder gun voltage pro-
cedure setting if necessary.
MAKING A WELD WITH THE SPOOL GUN
ADAPTER KIT AND SPOOL GUN
INSTALLED
CAUTION
In either toggle switch position, closing either gun
trigger will cause the electrode of both guns to be
electrically āHOTā. 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 āNormalā
position and pulling the trigger for the built-in feeder
gun.
ā¢
ā¢
Disables spool gun operation and spool gun gas
solenoid valve.
Closing feeder gun trigger starts feeder gun
welding and makes both electrodes electrically
āHOTā.
2. Setting spool gun selector switch to the Spool Gun
Position and pulling SPOOL GUN Trigger.
ā¢
ā¢
ā¢
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
āHOTā.
3. Operation with POWER MIGĀ® 215:
ā¢
ā¢
Turn the POWER MIGĀ®-215 input power ON.
Adjusting the voltage tap control will increase or
decrease your welding voltage.
ā¢
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 MIGĀ® Panel has
no affect on the spool gunās wire feed speed.
4. Refer to the procedure decal on the POWER MIGĀ®
for initial aluminum settings. Make a test weld to
determine the final settings.
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C-4
C-4
NOTES
POWER MIGĀ® 215
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Section D
Section D
TABLE OF CONTENTS
- MAINTENANCE SECTIONź¢-
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Gun Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories and replacement parts for Magnum
250L Gun & Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-4
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D-2
D-2
MAINTENANCE
3. If using optional adjustable slip-on nozzles, See
Table D.2 in this section.
SAFETY PRECAUTIONS
WARNING
ā¢
ā¢
Be sure the nozzle insulator is fully screwed onto
the gun tube and does not block the gas holes in
the diffuser.
ELECTRIC SHOCK can kill.
ā¢ Have an electrician install and
service this equipment.
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.
ā¢ Turn the input power off at the
fuse box before working on
equipment
ā¢ Do not touch electrically hot
parts.
* 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.
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.
The fan motors have sealed ball bearings which
require no service.
2. Remove spatter from inside of gas nozzle and from
tip after each 10 minutes of arc time or as required.
DRIVE ROLLS AND GUIDE PLATES
GUN CABLE CLEANING
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.
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.
CAUTION
For instructions on replacing or changing drive roll, see
āWire Drive Rollsā in Operation section.
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.
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.)
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D-3
D-3
MAINTENANCE
LINER REMOVAL AND REPLACE-
MENT
NOTE: Changing the liner for a different wire size
requires replacement of the gas diffuser per
Table D.1 to properly secure the different liner.
TABLE D.1
Fixed
Nozzle
Adjustable
Nozzle
Replacement Size Stencilled Gas Diffuser Gas Diffuser
Diameter of
Electrodes Used
Liner Part
Number
on End of
Part No.
Part No.
Liner Bushing (and Stencil) (and Stencil)
.025-.030" Steel
(0.6-0.8 mm)
KP1934-2
KP1934-1
KP1955-1
.030 (0.8 mm)
.045 (1.2 mm)
3/64" (1.2 mm)
KP2026-3
KP2026-3
KP2026-3
KP2026-2
KP2026-2
KP2026-2
.035-.045" Steel
(0.9-1.2 mm)
3/64" Aluminum
(1.2 mm)
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, 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.
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.
FIGURE D.1
SET SCREW
BRASS CABLE CONNECTOR
1-1/4"ź¢
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.
(31.8mm)ź¢
LINERź¢
TRIMź¢
LENGTH
SET SCREW
2. Remove the gas diffuser from the gun tube.
GAS DIFFUSER
NOZZLE INSULATOR (IF USED)
GAS NOZZLE
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.
CAUTION
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.
This screw should only be gently tightened.
Overtightening will split or collapse the liner and
cause poor wire feeding.
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 screw-
driver 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 ā .030"
.035 ā .045"
3/64"
0.6 ā 0.8 mm
0.9 ā 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
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) KP2010-5B1
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
Fi (Recessed)
Counterclockwise
Requires: Gas
Diffuser As'bly
KP2026-3 *
.025 ā .045"
0.6 ā 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
Asābly
Requires:
Gas Diffuser
Asābly
KP2026-2
KP2026-1
.025 ā .030"
.035 ā .045"
0.6 ā 0.8 mm
0.9 ā 1.2 mm
Gasless Nozzle
(For Innershield)
KP1947-1 ā
GUN TUBE ASSEMBLIES
Standard (60Ā°)
45Ā°
KP2015-1 *
KP2041-1
*
ā
Included with POWER MIGĀ® 215
Requires KP2026-1 Gas Diffuser Assembly.
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D-6
D-6
NOTES
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Section E
Section E
TABLE OF CONTENTS
- THEORY OF OPERATION SECTIONź¢-
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
FIGURE E.1 THEORY OF OPERATION BLOCK DIAGRAM
WIRE
GAS
SPEED
SOLENOID
CONTROL
WIRE
DRIVE
MOTOR
CONTROL BOARD
FAN
MOTOR
RECTIFIER
DIODE
BRIDGE
TRANSFORMER
THERMOSTAT
OUTPUT BRIDGE
THERMOSTAT
TACH
LINE
SWITCH
GUN TRIGGER
TAP SELECTOR
SWITCH
GUN
ASSEMBLY
OUTPUT DIODE
BRIDGE
+
+
POSITIVE
OUTPUT
CHOKE
TERMINAL
OUTPUT
CAPACITORS
CONTACTOR
-
-
RECONNECT
PANEL
MAIN
TRANSFORMER
NEGATIVE
TERMINAL
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 ā INPUT POWER CIRCUIT.
WIRE
SPEED
CONTROL
GAS
SOLENOID
WIRE
DRIVE
MOTOR
CONTROL BOARD
FAN
MOTOR
RECTIFIER
DIODE
BRIDGE
TRANSFORMER
THERMOSTAT
OUTPUT BRIDGE
THERMOSTAT
TACH
LINE
SWITCH
GUN TRIGGER
TAP SELECTOR
SWITCH
GUN
ASSEMBLY
OUTPUT DIODE
BRIDGE
+
+
POSITIVE
TERMINAL
OUTPUT
CHOKE
OUTPUT
CAPACITORS
CONTACTOR
-
-
NEGATIVE
TERMINAL
RECONNECT
PANEL
MAIN
TRANSFORMER
INPUT LINE VOLTAGE, MAIN
TRANSFORMER, VOLTAGE
SELECTOR SWITCH AND
BAFFLE MOUNTED DIODE
BRIDGE
The single phase input power is connected to
the POWER MIGĀ® 215 through a line switch
located on the front panel.
from a minimum setting (A) to a maximum
voltage setting (G). In addition, the main
transformer also has a 28VAC winding. This
28VAC is rectified at the baffle mounted diode
bridge. The resultant DC voltage (approx.
35VDC) is used to power the electronics on the
control board.
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
(120VAC) is powered from a portion of the
primary 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
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 ā CONTROL CIRCUITS.
WIRE
GAS
SPEED
SOLENOID
CONTROL
WIRE
DRIVE
MOTOR
CONTROL BOARD
FAN
MOTOR
RECTIFIER
DIODE
BRIDGE
TRANSFORMER
THERMOSTAT
OUTPUT BRIDGE
THERMOSTAT
TACH
LINE
SWITCH
GUN TRIGGER
TAP SELECTOR
SWITCH
GUN
ASSEMBLY
OUTPUT DIODE
BRIDGE
+
+
POSITIVE
OUTPUT
CHOKE
TERMINAL
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 diagrams are the subject of discussion.
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 ā OPTIONAL CIRCUITS.
WIRE
SPEED
CONTROL
GAS
SOLENOID
WIRE
DRIVE
MOTOR
CONTROL BOARD
FAN
MOTOR
RECTIFIER
DIODE
BRIDGE
TRANSFORMER
THERMOSTAT
OUTPUT BRIDGE
THERMOSTAT
TACH
LINE
SWITCH
GUN TRIGGER
TAP SELECTOR
SWITCH
GUN
ASSEMBLY
OUTPUT DIODE
BRIDGE
+
+
POSITIVE
TERMINAL
OUTPUT
CHOKE
OUTPUT
CAPACITORS
CONTACTOR
-
-
NEGATIVE
TERMINAL
RECONNECT
PANEL
MAIN
TRANSFORMER
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 0-5VDC signal from the wire
speed potentiometer and adjusts the motor
speed accordingly. 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 āopenā due to excessive heat,
the trigger circuit would be interrupted and the
machineās output and the wire feed would be
disabled. The board also contains overload
protection circuitry which protects the drive
motor from excessive current draw.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
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E-5
E-5
THEORY OF OPERATION
PROTECTIVE DEVICES AND CIRCUITS
WIREFEED OVERLOAD PROTECTION
THERMAL AND OVERLOAD PROTECTION
The POWER MIGĀ® 215 has solid state overload
protection of the wire drive motor. If the motor
becomes overloaded, the protection circuitry turns off
the wire feed speed and gas solenoid. Check for
proper size tip liner, drive rolls, and any obstructions
or bends in the gun cable. Check for any other
factors that would impede the wire feeding. To
resume welding, simply pull the trigger. There is no
circuit breaker to reset, as the protection is done with
reliable solid state electronics.
The POWER MIGĀ® 215 has two built-in protective
thermostats that respond to excessive temperatures.
One is located on the main transformer. The other
thermostat is located on the output rectifier heat sink
assembly. They open the wire feed and welder
output circuits if the machine exceeds the maximum
safe operating temperature. This can be caused by
a frequent overload or high ambient temperature.
The thermostats are self-resetting once the machine
cools sufficiently. If the thermostat shutdown is caused
by excessive output or duty cycle and the fan is
operating normally, the power switch may be left on
and the reset should occur within a 15 minute period.
If the fan is not turning or the air intake louver are
obstructed, then the input power must be removed
and the fan problem or air obstruction must be
corrected.
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E-6
E-6
NOTES
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Section F
Section F
TABLE OF CONTENTS
- TROUBLESHOOTINGź¢ANDź¢REPAIR SECTIONź¢-
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Bridge Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F-19
WARNING
ELECTRIC SHOCK can kill.
ā¢ 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.
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three step
procedure below.
Step 3. PERFORM COMPONENT TESTS.
The last column labeled āRECOMMENDED
COURSE OF ACTIONā lists the most likely
components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject
component is either bad or good. 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 PROBLEM (SYMPTOM).
Look under the column labeled āPROBLEM
(SYMPTOMS)ā. This column describes
possible symptoms that the machinery may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Symptoms are grouped according to:
feeding problems and function problems.
All the necessary test specifications and
repair procedures are described in detail
following the troubleshooting guide. All
electrical test points, terminal strips,
junctions, etc., can be found on the
electrical wiring diagrams and schematics
in the Electrical Diagram Section.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled āPOSSIBLE
AREAS OF MISADJUSTMENT(S)ā lists the
obvious external possibilities that may
contribute to the machine symptom.
Perform these tests/checks in the order
listed. In general, these tests can be
conducted without 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
- Tools which come in contact with the PC
WARNING
ELECTRIC SHOCK
can kill.
board must be either conductive, anti-static or
static-dissipative.
- Remove the PC board from the static-shield-
ing bag and place it directly into the equip-
ment. Donāt set the PC board on or near paper,
plastic or cloth which could have a static
charge. If the PC board canāt be installed
immediately, put it back in the static-shielding
bag.
ā¢
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, donāt remove them until installation is
complete.
CAUTION
Sometimes machine failures appear to be due
to PC board failures. These problems can
sometimes be traced to poor electrical con-
nections. To avoid problems when trou-
bleshooting and replacing PC boards, please
use the following procedure:
- 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 proper failure analysis.
4. Test the machine to determine if the
failure symptom has been corrected by
the replacement PC board.
1. Determine to the best of your technical
ability that the PC board is the most
likely component causing the failure
symptom.
NOTE: It is desirable to have a spare
(known good) PC board available for PC
board troubleshooting.
2. Check for loose connections at the PC
board to assure that the PC board is
properly connected.
NOTE: Allow the machine to heat up so that
all electrical components can reach their
operating temperature.
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:
5. Remove the replacement PC board and
substitute it with the original PC board
to recreate the original problem.
a. If the original problem does not
reappear by substituting the original
board, then the PC board was not
the problem. Continue to look for
bad connections in the control wiring
harness, junction blocks, and
terminal strips.
PC board can be
damaged by static
electricity.
- Remove your bodyās
static charge before
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.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
opening
the
static-
shielding bag. Wear an
anti-static wrist strap. For
safety, use a 1 Meg ohm
resistive cord connected
to a grounded part of the
equipment frame.
6. Always indicate that this procedure was
followed when warranty reports are to
be submitted.
- If you donāt 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.
NOTE: Following this procedure and writing
on the warranty report, āINSTALLED AND
SWITCHED PC BOARDS TO VERIFY PROB-
LEM,ā will help avoid denial of legitimate PC
board warranty claims.
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F-4
F-4
TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
Troubleshooting Guide ā See Wiring Diagrams for location of specified
components and for troubleshooting of specific circuits.
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.
1. Check the input power switch
(S1). It may be faulty.
1. Make certain the input power
switch (S1) is in the āONā
position.
The machine is dead--no open
circuit voltage and no wire feed
when the gun trigger is activated.
The cooling fan is not running.
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 wire feed when the gun trigger
is activated. The cooling fan is
running.
1. Make sure the input voltage is 1. The baffle mounted rectifier
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
machineās 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
F-5
TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
Troubleshooting Guide ā See Wiring Diagrams for location of specified
components and for troubleshooting of specific circuits.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS (Continued)
(continued from previous page)
3. Check the gun trigger leads.
Leads #324 to #325 should
have continuity (zero ohms)
when the gun trigger is activat-
ed. If not, the gun trigger or
cable may be faulty. Check or
replace.
4. If a spool gum option kit is
installed, check to make sure it
is set to the ānormalā position if
using the POWER MIGĀ® 215
built in wire feeder.
When the gun trigger is activated 1. Make sure the gun cable and 1. Check the output selector
and the wire feeds normally, but
there is no open circuit voltage.
work cables are connected
properly and in good condition.
switch for proper operation and
good connections.
switch is in a good condition
position and not between posi-
tions.
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
F-6
TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
Troubleshooting Guide ā See Wiring Diagrams for location of specified
components and for troubleshooting of specific circuits.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS (Continued)
Output voltage and wire feed speed 1. Remove the gun assembly. If 1. Check for āshortsā in the trigger
is present when the gun trigger is
NOTź¢activated.
the problem is resolved, the gun
assembly is faulty. Repair or
replace. If the problem is NOT
resolved, the fault is within the
POWER MIGĀ® 215 machine.
circuitry within the POWER
MIGĀ® 215 machine. See the
Wiring Diagram.
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-
nections on the heavy current
carrying leads inside the
POWER MIGĀ® 215. See the
Wiring Diagram.
are ācoldā. The weld beads are
rounded or āhumpedā 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.
2. Make sure the settings for wire
feed speed and voltage are cor-
rect for the process being used.
2. The output capacitors may be
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
in these capacitors is toxic.
Avoid contact with any portion of
your body.
4. Check the welding cables and
gun for loose or faulty connec-
tions.
3. The output selector switch may
be faulty. Check for good con-
tact and continuity (zero ohms)
through the switch. See the
Wiring Diagram.
1. Perform the Output Contactor
The output voltage is continuous 1. The output contactor may be
when the gun trigger is NOT activat-
ed. The wire feed functions normal-
ly.
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.
POWER MIGĀ® 215
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F-7
F-7
TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
Troubleshooting Guide ā See Wiring Diagrams for location of specified
components and for troubleshooting of specific circuits.
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. If a spool gun adapter is NOT
installed, make certain the
jumper plug is installed in J5.
See the Wiring Diagram.
3. Check the gas source and hoses
for kinks or leaks.
The machine stops feeding wire 1. Check for a mechanical restric- 1. Check the motor armature current.
while welding. When the gun trig-
ger is released and pulled again,
the wire feed starts.
tion 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
rotation.
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 MIGĀ® 215
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F-8
F-8
TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
Troubleshooting Guide ā See Wiring Diagrams for location of specified
components and for troubleshooting of specific circuits.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WIRE FEEDING PROBLEMS
1. The gun cable may be kinked or
twisted.
Rough wire feeding or the wire will
not feed but the drive rolls are turn-
ing.
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 potentiometer
Other machine functions are nor-
mal.
be dirty. Rotate several times
and check if the problem is
resolved.
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. 1. Perform the Wire Drive Motor and
trigger is activated. Normal open
circuit weld voltage is present and 2. If the drive rolls are turning,
the gas solenoid functions normally.
check for a mechanical restriction 2. The wire speed control potentiometer
in the wire feed path.
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
POWER MIGĀ® 215
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F-9
F-9
TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
Troubleshooting Guide ā See Wiring Diagrams for location of specified
components and for troubleshooting of specific circuits.
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 con-
tact with any portion of your body.
3. Make sure the machineās recon-
for the input voltage being
applied.
The arc is unstable and or āhuntingā 1. Check for a worn or melted con- 1. Check for loose or faulty connections
tact tip.
at the output terminals, choke, output
capacitors, output selector switch,
output contactor, and all heavy cur-
rent 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 elec-
trode 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 machineās 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 MIGĀ® 215
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F-10
F-10
TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
Troubleshooting Guide ā See Wiring Diagrams for location of specified
components and for troubleshooting of specific circuits.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The weld bead is narrow or ropy. 1. Make sure the welding proce- 1. Perform the Output Bridge Rectifier
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
ācontaminatedā.
these capacitors is toxic. Avoid con-
tact 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 MIGĀ® 215
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F-11
F-11
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER TEST
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 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 technical troubleshooting 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
3/8ā Nutdriver
5/16ā Nutdriver
Volt-ohmmeter
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F-12
F-12
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER TEST (continued)
FIGURE F.1. ā OUTPUT SELECTOR SWITCH TERMINALS
X4 X5
X3
X6
X2
X7
X8
TEST PROCEDURE
WARNING
7. Connect main input power to the
machine.
THE ON/OFF POWER SWITCH will be
āhotā during these tests.
8. Turn the POWER MIGź¢215 ON/OFF
Power Switch to the ON position.
NOTE: Secondary voltages will vary
proportionately with the primary
input voltage.
WARNING
ELECTRIC SHOCK can kill.
1. Disconnect the main input power
supply to the machine.
ā¢ Do not touch electrically live
parts such as output terminals
or internal wiring.
2. Remove the case top and side panels
with a 3/8ā nutdriver.
ā¢ All input power must be electri-
cally disconnected before pro-
ceeding.
3. Remove the tool tray with a 5/16ā nut
driver.
9. Carefully make the following voltage
4. Locate leads X2 thru X8 located on
the output selector switch. See Figure
F.1.
10. Turn off the machine.
11. If any of the voltages are incorrect
or missing, check for loose or broken
connections between the main
transformer and the test points.
5. Locate lead X1 located on the output
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F-14
F-14
TROUBLESHOOTING AND REPAIR
TABLE F.1. Test Points
INPUT VOLTAGE
TEST POINTS
X1-X2
EXPECTED VOLTAGE READING
230 VAC
230 VAC
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
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 missing, test for correct nameplate
input voltage between the H1 lead at the
ON/OFFź¢POWERź¢SWITCH to H2 or H3
at the reconnect panel. Voltage tested
will vary depending on input voltage con-
nection. 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 trans-
former 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/OFFź¢POWER SWITCH for
proper operation.
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F-15
F-15
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST
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 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 technical troubleshooting 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
5/16ā Nutdriver
Volt-Ohmmeter
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F-16
F-16
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST
(continued)
1. Make the following voltage tests:
Figure F.4 - Plug J4
Blackź¢
Tach
Blackź¢
Arm
WARNING
Whiteź¢
Arm
ELECTRIC SHOCK can kill.
ā¢ Do not touch electrically live
parts such as output terminals
or internal wiring.
ā¢ All input power must be electri-
cally disconnected before pro-
ceeding.
a. Turn the machine OFF between each test.
b. Carefully insert the meter probes into the lead side
of plug J4. See Figure F.4.
J11
Blueź¢
Tach
Redź¢
Tach
c. Turn the machine ON and pull the gun trigger to
conduct the voltage test.
FROM LEAD
FROM LEAD
FROM LEAD
Black
Armature
Lead
White
Armature
Lead
2-29 VDC
(varies depend-
ing on wire feed
speed)
2. 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 connector J5
for proper connections and jumper plug. See the
Wiring Diagram.
3. If all wires and connectors are good and the voltage
to the drive motor armature is zero, the control PC
board may be faulty. Replace the control PC board.
4. If the motor is running at high speed and the arma-
ture voltage is high and uncontrollable, replace the
control board.
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F-17
F-17
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST
(continued)
b. Carefully insert the meter probes
into the lead side of plug J1. See
Figure F5.
TEST FOR FEEDBACK VOLTAGE
TO CONTROL BOARD
1. Disconnect the main AC input power to
the machine.
c. Turn the machine ON and pull the
gun trigger to conduct the voltage
test.
2. Locate plug J1 and the potentiometer
leads. See Figure F.5. #1113A and
1109A.
EXPECTED
VOLTAGE
TO LEAD
FROM LEAD
3. Connect main input power to the
machine.
0 - 5 VDC
1113 A
1109 A
5. If the 0 to 5 VDC is present, the
potentiometer circuit is sending the
correct feedback signal to the control
PC board. Check the leads and plug
J1. See the Wiring Diagram.
WARNING
ELECTRIC SHOCK can kill.
ā¢ Do not touch electrically live
parts such as output terminals
or internal wiring.
ā¢ All input power must be electri-
cally disconnected before pro-
ceeding.
6. If the 0 to 5 VDC is NOT present or
NOT correct, the control PC board is
not receiving the proper feedback voltage
from the potentiometer circuit.
7. If the leads are okay, the potentiometer
circuit may be faulty, replace the
potentiometer circuit.
4. Make the following voltage tests:
a. Turn the machine OFF between
each test.
8. Replace the tool tray.
FIGURE F.5. ā PLUG J1
1103A
1
8
9
16
1109A
1113A
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F-18
F-18
NOTES
POWER MIGĀ® 215
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F-19
F-19
TROUBLESHOOTING AND REPAIR
OUTPUT BRIDGE RECTIFIER TEST
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 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 technical troubleshooting assistance before you proceed. Call 1-888-935-
3877.
TEST DESCRIPTION
This test will determine if a diode is āshortedā or āleakyā. See the machine waveform
section in this manual for normal and abnormal output wave forms.
MATERIALS NEEDED
Analog Volt-ohmmeter or Diode Tester
3/8ā Nutdriver
1/2ā Nutdriver
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F-20
F-20
TROUBLESHOOTING AND REPAIR
OUTPUT BRIDGE RECTIFIER TEST (continued)
4. Test for āshortedā or āleakyā diodes by
checking from the anodes to the cathodes
of the diode heatsink plates. The
TEST PROCEDURE
1. Remove input power to the POWER
MIGĀ® 215 machine.
readings should be high resistance in
one polarity and low resistance in the
opposite polarity.
2. Using the 3/8ā nutdriver, remove the left
case side.
5. If any of the diodes are āleakyā or
āshortedā the output rectifier assembly
should be replaced.
3. Locate and disconnect the negative lead
from the output rectifier bridge assembly.
Be sure there is no electrical contact
between the rectifier and the lead. See
Figure F.6.
6. When the test is complete, replace the
negative output lead previously removed.
7. Replace the left case side.
NOTE: Do not disassemble the rectifier
assembly.
Figure F.6. Rectifier Test Points
+
-
Negative Lead
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F-21
F-21
TROUBLESHOOTING AND REPAIR
CONTACTOR TEST
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 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 technical troubleshooting 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
7/16ā Wrench
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F-22
F-22
TROUBLESHOOTING AND REPAIR
CONTACTOR TEST (Continued)
12VDC is applied, check the resistance
TEST PROCEDURE
between the two large terminals with
the contactor activated. The resistance
should be very low (0 to 1 ohm).
1. Remove the input power to the POWER
MIGĀ® 215 machine.
8. If the resistance is āhighā or āopenā
between the two large terminals when
the contactor is activated, the contactor
is faulty. Replace.
2. Using the 5/16ā 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.
9. If the contactor activates and the
resistance between the terminals is low
when the 12 VDC is applied, the
contactor is good
4. Using the 7/16ā wrench, remove one
lead from the contactors large terminals.
See Figure F.7. See the Wiring Diagram.
NOTE: When the contactor is not activated,
the
the
resistance
between
terminals should be very high
(infinite). If the resistance is always
low, the contacts are āstuckā and
the contactor is faulty. Replace.
5. Carefully apply 12 VDC to the contactor
coil leads. (small terminals)
Do not leave the 12 VDC applied to the
contactor coil for a prolonged period of
time (15 seconds 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.
7. If the contactor activates when the
Figure F.7. Contactor Terminals and Leads
106B
106C
107A
Output
Contactor
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F-23
F-23
TROUBLESHOOTING AND REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
(MAX TAP āGā)
0 Volts
10.0 V
5 ms
MACHINE LOADED TO 200 AMPS AT 22 VDC
SCOPE SETTINGS
This is a typical DC output voltage wave-
form generated from a properly operat- Volts/Div.................................10V/Div
ing machine. Note that each vertical
division represents 10 volts and that Horizontal Sweep.................5 ms/Div
each horizontal division represents 5
milliseconds in time. The machine was Coupling........................................DC
loaded with a resistance grid bank.
Trigger....................................Internal
NOTE: Scope probes connected at
machine output terminals: (+)
probe to electrode, (-) probe to
work.
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F-24
F-24
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP āGā)
0 Volts
20.0 V
1.0 ms
SCOPE SETTINGS
This is a typical DC output voltage wave-
form generated from a properly operat- Volts/Div.................................20V/Div
ing machine. Note that each vertical
division represents 20 volts and that Horizontal Sweep..............1.0 ms/Div
each horizontal division represents 1.0
milliseconds in time.
Coupling........................................DC
NOTE: Scope probes connected at Trigger....................................Internal
machine output terminals: (+)
probe to electrode, (-) probe to
work.
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F-25
F-25
TROUBLESHOOTING AND REPAIR
ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE
LOADED (MAX TAP āGā)
ONE OUTPUT DIODE NOT FUNCTIONING
0 Volts
20.0 V
5 ms
MACHINE LOADED TO 180 AMPS AT 16 VDC
SCOPE SETTINGS
This is NOT a typical DC output voltage
waveform. One output diode is not func- Volts/Div.................................20V/Div
tioning. Note the increased ripple con-
tent. One diode was disconnected to Horizontal Sweep.................5 ms/Div
simulate an open or non-functioning out-
put diode. Each vertical division repre- Coupling........................................DC
sents 20 volts and each horizontal divi-
sion represents 5 milliseconds in time. Trigger....................................Internal
The machine was loaded with a resis-
tance grid bank.
NOTE: Scope probes connected at
machine output terminals: (+)
probe to electrode, (-) probe to
work.
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F-26
F-26
TROUBLESHOOTING AND REPAIR
ABNORMAL OPEN CIRCUIT VOLTAGE
OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP āGā)
0 Volts
20.0 V
5 ms
SCOPE SETTINGS
This is NOT a typical DC output voltage
waveform. The output capacitors are Volts/Div.................................20V/Div
not functioning. Note the lack of āfilter-
ingā in the output waveform. The output Horizontal Sweep.................5 ms/Div
capacitor bank was disconnected. Each
vertical division represents 20 volts and Coupling........................................DC
each horizontal division represents 5
milliseconds in time.
Trigger....................................Internal
NOTE: Scope probes connected at
machine output terminals: (+)
probe to electrode, (-) probe to
work.
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F-27
F-27
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REPLACEMENT
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 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 technical troubleshooting assistance before you proceed. Call 1-888-935-
3877.
DESCRIPTION
The following procedure will aid the technician in removing the Control Board for
replacement.
MATERIALS NEEDED
5/16ā Nutdriver
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F-28
F-28
TROUBLESHOOTING AND REPAIR
CONTROL BOARD REPLACEMENT (continued)
PROCEDURE
6. Carefully remove the control board.
1. Remove power to the machine.
7. Mount the new board to the nylon mounting
pins.
2. Using a 5/16ā nutdriver, remove the three
screws securing the tool tray.
8. Reconnect any plugs or leads previously
removed.
3. Locate the control board.
4. Disconnect all associated plugs and leads
connected 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.
FIGURE F.8. - CONTROL BOARD MOUNTING PINS
DEPRESS
LOCKING TAB ON
MOUNTING PIN
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F-29
F-29
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT
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 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 technical troubleshooting assistance before you proceed. Call 1-888-935-
3877.
DESCRIPTION
The following procedure will aid the technician in removing the Wire Drive and
Tachometer for repair or replacement.
MATERIALS NEEDED
5/16ā Nutdriver
9/16ā Nutdriver
Pliers
Small Flathead Screwdriver
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F-30
F-30
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued)
FIGURE F.9. - WIRE DRIVE LOCATION
Wire Drive
PROCEDURE
5. Using a 5/16ā nutdriver, remove the three
1. Remove power to the machine.
mounting screws next to the wire drive
2. Lift cover to gain access to the wire drive.
See Figure F.9.
6. Using a 5/16ā nutdriver, remove the two
3. Using a pair of pliers, disconnect the gas
hose from the bottom of the wire drive.
7. Carefully maneuver the wire drive assem-
bly out the side of the machine to gain
4. Using a 9/16ā nut driver, remove the thick
access to plug J4. See Wiring Diagram.
black positive lead located just above the
8. Disconnect plug J4.
NOTE: Disconnect lead from the wire drive
motor assembly, not the machine.
POWER MIGĀ® 215
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F-31
F-31
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued)
FIGURE F.10. - WIRE DRIVE HOSE & LEAD LOCATION
5/16" Sheet
Metal Screws
9/16" Bolt
Gas Hose
5/16"
Monuting
Screws
FIGURE F.11. - MOUNTING SCREW LOCATIONS
POWER MIGĀ® 215
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F-32
F-32
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued)
1. Place the new wire drive assembly into its 5. Using a 3/4ā nut driver, replace the thick
proper position.
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
position.
7. Close case wrap around cover.
4. Replace all mounting screws previously
removed.
POWER MIGĀ® 215
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F-33
F-33
TROUBLESHOOTING AND REPAIR
OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT
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 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 technical troubleshooting assistance before you proceed. Call 1-888-935-
3877.
DESCRIPTION
The following procedure will aid the technician in removing the Output Diode Bridge
rectifier for repair or replacement.
MATERIALS NEEDED
3/8ā Nutdriver
1/2ā Nutdriver
5/16ā Nutdriver
POWER MIGĀ® 215
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F-34
F-34
TROUBLESHOOTING AND REPAIR
OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)
PROCEDURE
7. Using a 1/2ā nutdriver remove the three bolts
1. Using a 3/8ā nutdriver, remove the left side of the
mounting the bracket to the rectifier. The rectifi-
case wraparound cover.
2. Locate the output diode bridge rectifier. See
Figure F.12.
8. Mount the new rectifier to the mounting bracket
using the three 1/2ā bolts.
3. Using a 1/2ā nutdriver label and remove the four
thick black leads connected to the rectifier.
9. Carefully manipulate the rectifier and mounting
NOTE: Be sure to label lead terminals also.
bracket as a one back into the machine to its
Take note of washer placement upon removal.
proper location.
4. Label and remove leads 104A and 104B. See
10. Mount the unit to the bottom of the machine
Wiring Diagram.
using the four 5/16ā mounting bolts previously
removed.
5. Using a 5/16ā nutdriver locate and remove the
four bolts mounting the rectifier bracket to the
11. Reconnect leads 104A and 104B previously
bottom of the machine. These bolts can be
removed.
accessed easily from the bottom of the machine.
12. Reconnect the four thick black leads previously
labeled and removed using a 1/2ā nutdriver.
6. Carefully manipulate the output diode bridge
rectifier and the mounting bracket out of the left
13. Replace the left side of the case wraparound
side of the machine.
cover.
FIGURE F.12. - OUTPUT DIODE BRIDGE RECTIFIER LOCATION
OUTPUT DIODE
BRIDGE
RECTIFIER
POWER MIGĀ® 215
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F-35
F-35
TROUBLESHOOTING AND REPAIR
OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)
FIGURE F.13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET
5/16" Mounting
Bracket Mounting
Bolts
1/2" Rectifier
Mounting
Mounting Bolts
Bracket
POWER MIGĀ® 215
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F-36
F-36
NOTES
POWER MIGĀ® 215
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F-37
F-37
TROUBLESHOOTING AND REPAIR
OUTPUT CAPACITORS REPLACEMENT
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 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 technical troubleshooting assistance before you proceed. Call 1-888-935-
3877.
DESCRIPTION
The following procedure will aid the technician in removing the Output Capacitors for
repair or replacement.
MATERIALS NEEDED
3/8ā Nutdriver
1/2ā Wrench
POWER MIGĀ® 215
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F-38
F-38
TROUBLESHOOTING AND REPAIR
OUTPUT CAPACITORS REPLACEMENT (Continued)
PROCEDURE
5. Remove the capacitor bank assembly from the
machine.
1. Using a 3/8ā nutdriver, remove the lower right
side case wraparound cover. See Figure F.14.
6. Place the new capacitor bank into its proper
location inside the machine.
2. Locate capacitor bank. See Figure F.14.
3. Label and remove the five leads connected to
the capacitor bank using a 1/2ā wrench. Note
7. Replace the three 3/8ā nuts and lock washers
previously removed.
8. Using a 1/2ā wrench, reconnect the five labeled
leads and associated washers previously
removed.
4. Using a 3/8ā 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.
FIGURE F.14. - CAPACITOR BANK LOCATION
LOWER RIGHT
CASE WRAPAROUND
COVER
CAPACITOR BANK
ASSEMBLY
POWER MIGĀ® 215
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F-40
F-40
NOTES
POWER MIGĀ® 215
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F-41
F-41
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER REPLACEMENT
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 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 technical troubleshooting assistance before you proceed. Call 1-888-935-
3877.
DESCRIPTION
The following procedure will aid the technician in removing the Main Transformer for
repair or replacement.
MATERIALS NEEDED
3/8ā Nutdriver
7/16ā Nutdriver
1/2ā Nutdriver
5/16ā Nutdriver
Flathead Screwdriver
POWER MIGĀ® 215
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F-42
F-42
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER REPLACEMENT (Continued)
PROCEDURE
7. Using a 1/2ā nutdriver, label and remove
lead X1 from the output diode bridge rectifi-
er.
1. Using a 3/8ā nutdriver, remove both sides of
the case wraparound cover.
2. Using a 5/16ā nutdriver, remove the tool tray.
8. Using a 5/16ā Nutdriver, open the rear
3. Locate the main transformer. See Figure
F.16.
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 dis-
connect lead H1B and other associated lead
connected to the same terminal. These
leads are connected to the ON/OFF switch.
11. Cut any necessary cable ties.
12. Remove any necessary wiring harnesses.
6. Using a 7/16ā nutdriver, Label and discon-
nect leads X8, X7, X6, X5, X4, X3, & X2 from
the switch assembly. Note washer position
14. Using a 1/2ā nutdriver, remove the four main
transformer mounting bolts and associated
washers. See Figure F.16.
FIGURE F.16. - MAIN TRANSFORMER LOCATION
Main Transformer
1/2" Mounting
Bolts
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F-43
F-43
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER REPLACEMENT (Continued)
15. Carefully maneuver the main transformer 5. Reconnect lead X1 to the output diode
out the left side of the machine.
bridge rectifier.
NOTE: Two people may be needed to maneu- 6. Reconnect leads X8, X7, X6, X5, X4, X3, &
ver the main transformer out of the
machine.
X2 previously removed from the switch
assembly.
7. Reconnect lead H1B and the other associat-
ed lead connected to the same terminal.
These leads are connected to the ON/OFF
switch.
REPLACEMENT
1. Carefully maneuver the new main trans-
former back into the machine and onto its
mounting studs.
8. Replace any necessary cable ties and wiring
harnesses.
2. Using a 1/2ā 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 5/16ā nutdriver, replace the tool tray.
4. Using a 5/16ā nutdriver, close the rear
access panel previously opened.
11. Using a 3/8ā nutdriver, replace both sides of
the case wraparound cover.
FIGURE F.17. - LEADS X9, X10, 104B,104C, & H1B
104B
104C
X9
X10
H1B
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F-46
F-46
NOTES
POWER MIGĀ® 215
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F-47
F-47
TROUBLESHOOTING AND REPAIR
FAN BLADE/MOTOR REPLACEMENT
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 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 technical troubleshooting assistance before you proceed. Call 1-888-935-
3877.
DESCRIPTION
The following procedure will aid the technician in removing the Fan Blade and Fan Motor
for repair or replacement.
MATERIALS NEEDED
3/8ā Nutdriver
5/16ā Nutdriver
11/32ā Open-End Wrench
Flathead Screwdriver
POWER MIGĀ® 215
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F-48
F-48
TROUBLESHOOTING AND REPAIR
FAN BLADE/MOTOR REPLACEMENT (Continued)
PROCEDURE
1. Using a 3/8ā nutdriver, remove the lower 8. Replace the fan motor and fan blade if nec-
right side of the case wraparound cover. essary.
10. Carefully manuver the fan assembly into its
3. Using a 5/16ā nutdriver, remove the four fan
mounting screws from the rear of the
machine. See Figure F.22.
original position.
11. Replace the two 11/32ā fan motor mounting
nuts and lockwashers.
4. Using an open end 11/32ā wrench, remove
the two fan motor mounting nuts and lock- 12. Replace the four 5/16ā fan assembly mount-
washers. See Figure F.22. ing screws in the rear of the machine.
5. Using a flathead screwdriver, loosen the fan NOTE: Make sure the fan blade is free to rotate
when all of the mounting bolts are
replaced.
blade mounting band. See Figure F.22.
6. Pry the fan blade off of the mounting shaft.
7. Carefully manuver the fan motor and fan 14. Replace the lower right case cover.
blade out of the right side of the machine.
FIGURE F.22. - FAN MOUNTING BOLTS
REAR
Fan
Blade
Fan
Motor
Fan
Mounting
Band
11/32"
Mounting
Nuts
5/16" Bolts
POWER MIGĀ® 215
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F-49
F-49
TROUBLESHOOTING AND REPAIR
OUTPUT CONTACTOR REPLACEMENT
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 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 technical troubleshooting assistance before you proceed. Call 1-888-935-
3877.
DESCRIPTION
The following procedure will aid the technician in removing the Output Contactor for
repair or replacement.
MATERIALS NEEDED
7/16ā Wrench
5/16ā Nutdriver
POWER MIGĀ® 215
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F-50
F-50
TROUBLESHOOTING AND REPAIR
OUTPUT CONTACTOR REPLACEMENT (Continued)
PROCEDURE
1. Using a 5/16ā nutdriver, remove the three 7. Replace output contactor.
screws securing the tool tray.
8. Using a 7/16ā wrench, mount the new output
contactor in its proper location.
2. Locate the output contactor. See Figure
F.23.
9. Reconnect leads 106B, 106C, & 107A to
their proper terminals. See Wiring Diagram.
3. Using a 7/16ā wrench, label and remove the
two thick black leads at the top of the output
contactor. Note lead and washer placement 10. Reconnect the two thick black leads previ-
for reassembly.
ously removed from the top of the output
contactor.
4. Remove lead 107A and note lead place-
ment. See Figure F.23.
11. Replace the tool tray using a 5/16ā nutdriv-
er.
5. Remove leads 106B and 106C. See Figure
F.23.
6. Using a 7/16ā wrench, remove the three
mounting bolts from the output contactor.
FIGURE F.23. - OUTPUT CONTACTOR LEADS
106B
106C
107A
Output
Contactor
POWER MIGĀ® 215
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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)
POWER MIGĀ® 215
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G
WIRING DIAGRAM - COMPLETE MACHINE - CODE 11070 - (L11986) . . . . . . . . . . . . . . . . . . . . . G-2
WIRING DIAGRAM - COMPLETE MACHINE - CODE 11099, 11247 - (L12184) . . . . . . . . . . . . . . . G-3
SCHEMATIC - COMPLETE MACHINE - CODE 11247 - (L12308/1). . . . . . . . . . . . . . . . . . . . . . . . . G-4
SCHEMATIC - COMPLETE MACHINE - CODE 11247 - (L12308/2). . . . . . . . . . . . . . . . . . . . . . . . . G-5
SCHEMATIC - COMMON ANALOG WIREDRIVE PCź¢BOARD - CODE 11070 - (G3850 PG1) . . . . G-6
SCHEMATIC - COMMON ANALOG WIREDRIVE PCź¢BOARD - CODE 11070 - (G3850 PG2) . . . . G-7
SCHEMATIC - COMMON ANALOG WIREDRIVE PCź¢BOARD - CODE 11070 - (G3850 PG3) . . . . G-8
SCHEMATIC-COMMON ANALOG WIREDRIVE PCź¢BOARD-CODE 11099, 11247 - (G4414 PG1). G-9
SCHEMATIC-COMMON ANALOG WIREDRIVE PCź¢BOARD-CODE 11099, 11247 - (G4414 PG2). G-10
SCHEMATIC-COMMON ANALOG WIREDRIVE PCź¢BOARD-CODE 11099, 11247 - (G4414 PG3). G-11
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered
and are therefore considered to be unserviceable. Assembly drawings of these boards are no
longer provided.
POWER MIGĀ® 215
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G-2
G-2
ElEcTrical DiaGramS
WiriNG DiaGram - cOmplETE machiNE - cODE 11070 - (l11986)
POWER MIG 215 (208/220/230V)
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.
CONTROL BOARD
C
AVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
N.B.
THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY āPOSITIVEā. TO CHANGE POLARITY, TURN
THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK
STUD.
B
-
BLACK
WHITE
RED
W -
R -
U -
1
8
1
3
6
1
2
BLUE
J1
J2
J3
1
2
1101A
16
9
4
INDICATES CONNECTOR CAVITY No.
1102A
1103A
RECTIFIER
ASSEMBLY
TRANSFORMER
THERMOSTAT
THERMOSTAT
3
** CAVITY
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
5
1
3
6
PA
J1
1103A
R2
4
8
9
1109A
1110A
1111A
10
11
12
13
1109A
1113A
W
IR
E
FEED
1112A
1113A
SPEED
1114A
1115A
1116A
14
15
1108A
16
1106A X9
X10
1114A
J5
PA**
3
4
5
6
1116A
B
AFFLE
MOUN ED
RECTIFIER
DIODE
BRIDG
T
1
2
1
1116B
1104C
1105A
1106C
GAS
SOLENOID
2
E
X10
3
4
5
6
1116B
27.8V
1106
1107A
C
1106B
1104D
1105B
1106B
X9
X8
X7
X6
X5
X4
X3
X2
X1
G
F
JUMPER PLUG
INSTALLED FOR
NON-SPOOL GUN
OPERATION
GUN
TRIGGER
J6
H1
L2
L1
1
SINGLE PHASE
BRIDGE
RECTIFIER
1
324
325
E
D
C
B
A
1111A
1104D
2
3
2
3
H2
H3
H4
L1
L2
J4
T
O
S
INGLE PHASE
4
1
**
1115A
4
CONTACTOR
SUPPLY LINE
H2
220
230
208V
2
3
4
V
H1
H4
W
R
U
B
1101A
1102A
TAP SELEC
SW TCH
TOR
B
I
H1
5
6
7
8
RECONNECT
ANEL
H3
P
L
SW
INE
ITCH
1112A
1105B
G
B
P
OWER
TRANSFORMER
S1
X11
X12
W
115V
T
O
GROUND PER
IONAL ELECTRICAL
CODE
NA
T
1
2
3
J2
4
5
6
B
15A
+
401A
401
403
MOTOR
/
P.M.
X11
CIRCUIT
GEAR OX
B
R
U
B
T
A
C
H
BREAKER
-
FAN
115V
MOTOR
TO
W
W
ORK
1
2
X12
J3
402A
402
40 OHMS
50 W
C1
C2
C1 AND C
31,000 MFD
50V
2
+
+
OUTPU
CHOK
T
E
A
L11986
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
pOWEr miGĀ® 215
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G-3
G-3
ElEcTrical DiaGramS
WiriNG DiaGram - cOmplETE machiNE - cODE 11099, 11247 - (l12184)
POWER MIG 215 (208/220/230V)
FOR CODES 11099 AND 11247
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.
CONTROL BOARD
C
AVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C.
N.B.
THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY āPOSITIVEā. TO CHANGE POLARITY, TURN
THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK
STUD.
B
OARD)
B
-
BLACK
WHITE
RED
W -
R -
U -
1
8
1
3
6
1
2
BLUE
J1
J2
J3
1
2
1101A
16
9
4
INDICATES CONNECTOR CAVITY No.
1102A
1103A
RECTIFIER
ASSEMBLY
TRANSFORMER
THERMOSTAT
THERMOSTAT
3
** CAVITY
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
5
1
3
6
PA
J1
1103A
R2
4
8
9
1109A
1110A
1111A
10
11
12
13
1109A
1113A
W
IR
E
FEED
1112A
1113A
SPEED
1114A
1115A
1116A
14
15
1108A
16
J5
PA**
3
4
5
6
1116A
1
2
1
1116B
1104C
1105A
1106C
GAS
SOLENOID
2
1110A
1114A
X10
3
4
5
6
1116B
27.8V
1106
C
1107A
1106A
1104D
1105B
X9
X8
X7
X6
X5
X4
X3
X2
X1
G
F
JUMPER PLUG
INSTALLED FOR
NON-SPOOL GUN
OPERATION
GUN
TRIGGER
J6
H1
L2
L1
1
SINGLE PHASE
BRIDGE
RECTIFIER
1
324
325
E
D
C
B
A
1111A
1104D
2
3
2
3
H2
H3
H4
L1
L2
J4
T
O
S
INGLE PHASE
4
1
**
1115A
4
CONTAC
T
OR
SUPPLY LINE
H2
220
230
208V
2
3
4
V
H1
H4
W
R
U
B
1101A
1102A
TAP SELEC
SW TCH
TOR
B
I
H1
5
6
7
8
RECONNECT
ANEL
H3
P
L
INE
SW TCH
S1
I
1112A
1105B
G
B
P
OWER
TRANSFORMER
X11
X12
W
115V
T
O
GROUND PER
IONAL ELECTRICAL
CODE
NA
T
1
2
3
J2
4
5
6
B
15A
D
+
401A
401
403
MOTOR
/
P.M.
X11
GEAR OX
B
D
T
A
C
H
-
U
FAN
115V
B
MOTOR
TO
W
W
ORK
1
2
X12
J3
402A
402
40 OHMS
50 W
C1
C2
+
C1 AND C
31,000 MFD
50V
2
+
OUTPU
CHOK
T
E
R.F. FILTER
E
L12184PRINT
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
pOWEr miGĀ® 215
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ElEcTrical DiaGramS
SchEmaTic - cOmplETE machiNE - cODE 11247 - (l12308 pG1)
8 0 3 2 L 1
CHANG
E
DETAIL: NEW.
ENGINEERING CONTROL
LED
MANUFACTURER:
No
ON CODE 11099 AND HIGHER
FRONT
TOP
LEFT
FR
FR
O
O
M
M
X
X9
10
10J1
14J1
CONTROL
P.C. OARD
B
+39.25VDC
COM
CONTACTOR
(SCHEMATIC G3850)
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
SOLENOI
D
-
MOVED
TO CON
TRO
L
20OHMCOIL
6VHOLD
LOCATED
ONRIGHT
CASE BACK
BOARD ON CODE 1109
AND HIGHER
9
LOCATED IN P.C. BOARD
COMPARTMENT
LOCATED ON
TRANSFORMER
BAFFLE
X10
1105A
3J5
6J5
MOTOR USE
1106B
1105B
1J3
2J3
SOLENOID/SPOOL
GUN DETECT USE
1116B
1J5
5J5
4J5
2J5
1104D
1106C
1104C
SPOOL GUN ADAPTER
PANEL CONNECTIONS
(SEEPAGE2)
6J2
GUN TRIGGER
USE
3J2
2J2
1J2
4J2
LOCATED ON
MAIN
TRANSFORMER
WINDINGS
LOCATED ON
INPUT
RECTIFIER
FRONT OF DRIVE
ROLL AREA
G
UN
T
RIGGER
1104A
11J4
11J1
1104B
N.C.
1
324
325
4J6
2J6
N.C.
1111A
2
3
LOCATED INSIDE
OF P.C. BOARD
COMPARTMENT
CONTROL
BOARD
POWER
14J1
10J1
4
ON CODE 11099 AND HIGHER
LOCATED INSIDE OF
P.C. BOARD COMPARTMENT
M
M
OT
OT
O
O
R +
R -
W
8J4
7J4
5J1
12J1
1105A
1112A
B
B
W
TOROID
(1 TURN)
LOCATED ON FRONT
OF MACHINE'SBASE
MOTOR / GEARBOX
TACH
OHMS = 1.5 TO 6.5
1.8 VDC @50 IN/MIN
26.5 VDC @700 IN/MIN
5VDC TACH SUPPLY
MAIN
TRANSFORME
R
U
B
R
U
B
3J4
4J4
5J4
15J1
1J1
2J1
1115A
1101A
1102A
R
TACH SIGNAL
TACH COM
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
D
J1
J2
J3
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
HIS DOCUME
N
T CONTAINS P
D
R
OPRIETARY INFORMATIO
U
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
W
N
D MAY NOT BE
D
UPLICATED,
OLN GLOBAL, INC.
COMMUNICATE
D
PROPRIETARY & CONFIDENTIAL:TTO OT
HER PARTIES OR USE
FOR ANY P
RPOSE WITHOUT THE EXPRESS
RITTEN PERMISSIO
N
OF LIN
C
THE INFORMATION ON THIS
DESIGN INFORM
A
TION
cstuble
NGINEER: J. SKERBEC
APPROVED:
REFERENCE:
-
EQUIPMENT TYPE
SUBJECT:
:
_1__
_2__
OF
POWER MIG 215
PAGE
DOCUMENT
UMB R:
PRINT IS FOR REFERENC
E
DRAWN BY:
ONLY. COMPONENTS AND
DOCUMENT
REVISION:
MACHINE SCHEMATIC
N
E
CIRCUITRY MA
Y
BE
E
SCALE:
DIFFERENT
FROM AN ACTUAL MACHINE.
MATERIAL
UF
APPROVAL
DATE:
PROJECT
NUMBER:
L12308
A
CRM37681
12/8/200
5
-
NONE
DISPOSITION:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWEr miGĀ® 215
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ElEcTrical DiaGramS
SchEmaTic - cOmplETE machiNE - cODE 11247 - (l12308 pG2)
8
1 2 L 3 0
CHANG
E
DETAIL: NEW.
ENGINEERING CONTROLLED
MANUFACTURER:
No
CONTROLS THE
FUNCTIONALITY OF
THE MACHINE
CONTROL
P.C. OARD
(SCHEMATIC G3850)
B
PTC
FROM STANDARD
GUN TRIGGER
11J1
12J1
FROM 112A FEED
MOTOR NEG LEAD
.05
SPOOL
GUN
MOTOR
GAS SOLENOID
G
G
AS SOLENOID +
AS SOLENOID -
8VAC @50 IN/MIN
20VAC @700IN/MIN
6-PIN
AMPHENOL
LOCATED ON
CASE BACK
SPOOL GUN
ADAPTER
PANEL
M
OT
O
R +
A
B
M
OT
O
R -
WFS
100K
POT
V=8.7VDC WHEN GAS IS FLOWING
COIL: 21.6 OHMS, 12VDC COIL
LOCATED ON
C
D
E
F
SPOOL GUN POT
DIVIDERPANEL
INWIREDRIVE
COMPARTMENT
MOTOR + SPEED CONTROL
FROM CONTROL BOARD
(TOSWITCHBETWEEN
SPOOL GUN AND
STANDARD GUN)
TOGGLE
SWITCH
**
3J5
6J5
1J5
5J5
4J5
2J5
3PB
6PB
1PB
5PB
4PB
2PB
105C
105D
116C
104F
106D
104E
TO STANDARD FEED MOTOR
105E
SPOOL GUN TRIGGER
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
GUN ELECTRICALLY HOT!
104G
FROM STANDARD GUN TRIGGER
+40
NORMALLY CLOSED (SHOWN
INSPOOL GUNPOSITION)
CONTROLS THE
FUNCTIONALITY OF
THE MACHINE
TO CONTROL BOARD (TRIGGER)
THERMOSTAT
R
EF
ADAPT
INSTR
E
R TO L11543 FOR SPOOL GUN
PANEL INSTALLATIO
CTIONS.
FOR SPOOL G
JUMPER J5 FROM P5 OF MA
U
N
OPERATION, U
HINE
HARNESS
N
PLUG
**
E
U
R
N
C
H
ARNESS
AN PLUG SPOOL G
D
IN
UN
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
D
J1
J2
J3
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
HIS DOCUME
N
T CONTAINS P
TIES O USED
R
OPRIETARY INFORMATIO
U
N
OWNED BY LIN
C
OLN GLOBAL, INC. A
W
N
D MAY NOT BE
D
OLN GLOBAL, INC.
UPLICATED,
COMMUNICATE
D
PROPRIETARY & CONFIDENTIAL:TTO OT
HER PA
R
R
FOR ANY P
RPOSE WITHOUT THE EXPRESS
RITTEN PERMISSIO
N
OF LIN
C
THE INFORMATION ON THIS
DESIGN INFORM
A
TION
cstuble
NGINEER: J. SKERBEC
APPROVED:
REFERENCE:
-
EQUIPMENT TYPE
SUBJECT:
:
_2__
_2__
OF
POWER MIG 215
PAGE
DOCUMENT
UMB R:
PRINT IS FOR REFERENC
E
DRAWN BY:
ONLY. COMPONENTS AND
DOCUMENT
REVISION:
MACHINE SCHEMATIC
N
E
CIRCUITRY MA
Y
BE
E
SCALE:
DIFFERENT
FROM AN ACTUAL MACHINE.
MATERIAL
UF
APPROVAL
DATE:
PROJECT
NUMBER:
L12308
A
CRM37681
12/8/200
5
-
NONE
DISPOSITION:
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWEr miGĀ® 215
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11070 - (G3850 pG1)
G-6
ElEcTrical DiaGramS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWEr miGĀ® 215
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11070 - (G3850 pG2)
G-7
ElEcTrical DiaGramS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWEr miGĀ® 215
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11070 - (G3850 pG3)
G-8
ElEcTrical DiaGramS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWEr miGĀ® 215
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11099, 11247 - (G4414 pG1)
G-9
ElEcTrical DiaGramS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWEr miGĀ® 215
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11099, 11247 - (G4414 pG2)
G-10
ElEcTrical DiaGramS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWEr miGĀ® 215
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11099, 11247 - (G4414 pG3)
G-11
ElEcTrical DiaGramS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
pOWEr miGĀ® 215
Download from Www.Somanuals.com. All Manuals Search And Download.
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