Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
POWER MIG® 215 SAFETY i i FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engin...
Page 3 - ii; ELECTRIC SHOCK can kill.
SAFETY ii ii POWER MIG® 215 FUMES AND GASEScan be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep fumes and gases away from the breathing...
Page 4 - iii; Refer to
CYLINDER may explodeif damaged. 7.a. Use only compressed gas cylinders containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition. 7...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY iv iv POWER MIG® 215 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous co...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
v v POWER MIG® 215 MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 7 - TABLE OF CONTENTS; Section A
TABLE OF CONTENTS - INSTALLATION SECTION - POWER MIG® 215 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Safety Preca...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – POWER MIG® 215
POWER MIG® 215 A-2 A-2 INSTALLATION 75°C Copper Wire 75°C Copper Wire Input Ampere in Conduit in Conduit Input Voltage/ Fuse or Breaker Rating On AWG (IEC) Sizes AWG (IEC) Sizes (For lengths (For lengths Frequency (Hz) Size (Super Lag) Nameplate up to 100 ft.) exceeding 100 ft.) 208/50/60 60 45A 10 ...
Page 9 - SAFETY PRECAUTIONS; Before starting the installation, check with the local
INSTALLATION A-3 POWER MIG® 215 A-3 Read entire installation section before startinginstallation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and under- stood the POWER MIG® 215 OperatingManual should instal...
Page 10 - Technical; FIGURE A.2 — Receptacle Diagram; OUTPUT POLARITY CONNECTIONS
INSTALLATION A-4 POWER MIG® 215 A-4 3. The 208/230 volt 50/60 Hz model POWER MIG® is shipped with a 7 ft.(2.1m). input cable and plug con-nected to the welder. 4. Using the instructions in Figure A.2, have a qualified electrician connect a receptacle (CustomerSupplied) or cable to the input power li...
Page 11 - GUN AND CABLE INSTALLATION; AUXILIARY POWER RECEPTACLES
INSTALLATION A-5 POWER MIG® 215 A-5 GUN AND CABLE INSTALLATION The Magnum 250L gun and cable provided with thePOWER MIG® 215 is factory installed with a liner for.035-.045" (0.9-1.2 mm) electrode and an .035" (0.9mm) contact tip. Be sure that the contact tip, liner, anddrive rolls all match ...
Page 12 - NOTES
NOTES A-6 A-6 POWER MIG® 215 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC
Page 13 - Section B
TABLE OF CONTENTS - OPERATION SECTION - POWER MIG® 215 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Safety Precautions ................................................................................................B-2Produ...
Page 14 - OPERATION
OPERATION B-2 B-2 POWER MIG® 215 Read entire Operation section beforeoperating the POWER MIG® 215. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet cloth-ing. Insulate yourself from workand ground. • Always wear dry insulating gloves. FUMES AND GASES can ...
Page 15 - Place the lever in the; Voltage Control —; Seven voltage tap selections; Wire Speed Control —; This controls the wire feed
POWER MIG® 215 B-3 B-3 OPERATION PRODUCT DESCRIPTION The POWER MIG® 215 is a complete semiautomaticDC voltage arc welding machine built to meet NEMAspecifications. It combines a tapped transformer volt-age power source with a constant speed wire feeder toform a reliable robust performance welding sy...
Page 16 - TO START THE WELDER
B-4 B-4 OPERATION POWER MIG® PROCEDURE FOR CHANGINGDRIVE AND IDLE ROLL SETS 1. Turn off the power source. 2. Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back ofthe machine. Lift the cast idle roll assembly andallow it to sit in an upright position. 3...
Page 17 - FEEDING WIRE ELECTRODE; Accessories; IDLE ROLL PRESSURE SETTING; WIRE DRIVE CONFIGURATION
OPERATION B-5 B-5 POWER MIG® 215 FEEDING WIRE ELECTRODE When triggering, the electrode anddrive mechanism are electrically “hot”relative to work and ground andremain “hot” several seconds after thegun trigger is released. ------------------------------------------------------------------------NOTE: ...
Page 18 - • When using an open arc process, it; Important: Do not attempt to completely; MAKING A WELD
OPERATION B-6 B-6 POWER MIG® 215 3. Press the trigger to feed the wire electrode through the gun and cable. For solid wire cut the electrodewithin approximately 3/8" (10 mm) of the end of thecontact tip [3/4" (20 mm) for Outershield®]. 4. When welding with gas, turn on the gas supply and set...
Page 19 - FAN CONTROL; High Line Voltage; WELDING THERMAL OVERLOAD; Wire Feed Speed/Voltage Tap Settings
OPERATION B-7 B-7 POWER MIG® 215 9. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn offPOWER MIG® 215. NOTE: When using Innershield electrode, the gasnozzle may be removed from the insulation onthe end of the...
Page 21 - Section C
TABLE OF CONTENTS - ACCESSORIES SECTION - POWER MIG® 215 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 3/64” (1....
Page 22 - ACCESSORIES; DRIVE ROLL KITS; Bold
ACCESSORIES C-2 C-2 POWER MIG® 215 DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that areavailable for the POWER MIG® 215.The item in Bold is supplied standard with the POWER MIG® 215. TABLE C.1 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1) This kit helps push feeding aluminum t...
Page 23 - CAUTION
ACCESSORIES C-3 C-3 POWER MIG® 215 MAKING A WELD WITH THE SPOOL GUNADAPTER KIT AND SPOOL GUNINSTALLED In either toggle switch position, closing either guntrigger will cause the electrode of both guns to beelectrically “HOT”. Be sure unused gun is posi-tioned so electrode or tip will not contact meta...
Page 25 - Accessories and replacement parts for Magnum; Section D
TABLE OF CONTENTS - MAINTENANCE SECTION - POWER MIG® 215 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 General Maintena...
Page 26 - MAINTENANCE; • Have an electrician install and; GENERAL MAINTENANCE; Table; See; GUN TUBES AND NOZZLES
MAINTENANCE D-2 D-2 POWER MIG® 215 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working onequipment • Do not touch electrically hot parts. GENERAL MAINTENANCE In extremely dusty locations, dirt...
Page 27 - not
MAINTENANCE D-3 D-3 POWER MIG® 215 LINER REMOVAL AND REPLACE-MENT NOTE: Changing the liner for a different wire sizerequires replacement of the gas diffuser perTable D.1 to properly secure the different liner. Fixed Adjustable Nozzle Nozzle Replacement Size Stencilled Gas Diffuser Gas Diffuser Diame...
Page 28 - GUN HANDLE DISASSEMBLY; ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS
MAINTENANCE D-4 D-4 POWER MIG® 215 GUN HANDLE DISASSEMBLY The internal parts of the gun handle may beinspected or serviced if necessary. The gun handle consists of two halves that areheld together with a collar on each end. To openup the handle, turn the collars approximately 60degrees counterclockw...
Page 29 - FIGURE D.2 – MAJOR COMPONENT LOCATIONS
MAINTENANCE D-5 D-5 POWER MIG® 215 6 2 3 4 5 1 1. Case Front Assembly2. Rear Panel Assembly3. Center Assembly4. Wire Drive Assembly5. Base & Power Component Assembly6. Covers Assembly FIGURE D.2 – MAJOR COMPONENT LOCATIONS Return to Section T OC Return to Section T OC Return to Section T OC Retu...
Page 31 - Section E; FIGURE E.1 THEORY OF OPERATION BLOCK DIAGRAM
TABLE OF CONTENTS - THEORY OF OPERATION SECTION - POWER MIG® 215 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 Input Line ...
Page 32 - THEORY OF OPERATION
THEORY OF OPERATION E-2 E-2 POWER MIG® 215 FIGURE E.2 – INPUT POWER CIRCUIT. INPUT LINE VOLTAGE, MAINTRANSFORMER, VOLTAGESELECTOR SWITCH ANDBAFFLE MOUNTED DIODEBRIDGE The single phase input power is connected tothe POWER MIG® 215 through a line switchlocated on the front panel. A reconnect panel all...
Page 35 - PROTECTIVE DEVICES AND CIRCUITS; THERMAL AND OVERLOAD PROTECTION
THEORY OF OPERATION E-5 E-5 POWER MIG® 215 PROTECTIVE DEVICES AND CIRCUITS THERMAL AND OVERLOAD PROTECTION The POWER MIG® 215 has two built-in protectivethermostats that respond to excessive temperatures.One is located on the main transformer. The otherthermostat is located on the output rectifier h...
Page 37 - Section F; ELECTRIC SHOCK can kill.; • Never work on the inside of the machine without removing the
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - POWER MIG® 215 Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2 PC Board Troubleshooting...
Page 38 - TROUBLESHOOTING AND REPAIR
F-2 TROUBLESHOOTING AND REPAIR F-2 POWER MIG® 215 If for any reason you do not understand the test procedures or are unable to perform thet e s t s / r e p a i r s s a f e l y, c o n t a c t t h e L i n c o l n E l e c t r i c S e r v i c e D e p a r t m e n t f o r t e c h n i c a ltroubleshooting ...
Page 39 - PC BOARD TROUBLESHOOTING PROCEDURES
F-3 TROUBLESHOOTING AND REPAIR F-3 POWER MIG® 215 Sometimes machine failures appear to be dueto PC board failures. These problems cansometimes be traced to poor electrical con-nections. To avoid problems when trou-bleshooting and replacing PC boards, pleaseuse the following procedure: 1. Determine t...
Page 40 - OUTPUT PROBLEMS; Troubleshooting Guide –; Main Transformer
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-4 TROUBLESHOOTING AND REPAIR F-4 POWER MIG® 215 PROBLEMS(SYMPTOMS) POSSIBLE AREAS OFMIS...
Page 41 - If a spool gum option kit is
When the gun trigger is activatedand the wire feeds normally, butthere is no open circuit voltage. OUTPUT PROBLEMS (Continued) TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified componen...
Page 42 - Output Contactor
OUTPUT PROBLEMS (Continued) Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. The machines output is low. Weldsare “cold”. The weld beads arerounded or “hu...
Page 43 - Lincoln Electric Service Department; FUNCTION PROBLEMS
TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-7 F-7 POWER MIG® 215 If for any reason you do not understand the test proced...
Page 44 - WIRE FEEDING PROBLEMS; Wire Drive Motor and
TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-8 F-8 POWER MIG® 215 If for any reason you do not understand the test proced...
Page 45 - WELDING PROBLEMS; Output Bridge Rectifier
TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-9 F-9 POWER MIG® 215 If for any reason you do not understand the test proced...
Page 46 - Make certain the shielding gas is
TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual. Troubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-10 F-10 POWER MIG® 215 If for any reason you do not understand the test proc...
Page 47 - TEST DESCRIPTION; MAIN TRANSFORMER TEST
TROUBLESHOOTING AND REPAIR F-11 F-11 POWER MIG® 215 TEST DESCRIPTION This test will determine if the correct voltages are being applied.a. Applied to the primary windings of the Main Transformers.b. Induced on the secondary and auxiliary windings of the Main Transformer. MATERIALS NEEDED 3/8” Nutdri...
Page 48 - TEST PROCEDURE; See Figure; FIGURE F.1. – OUTPUT SELECTOR SWITCH TERMINALS
TEST PROCEDURE THE ON/OFF POWER SWITCH will be“hot” during these tests. NOTE: Secondary voltages will varyproportionately with the primaryinput voltage. 1. Disconnect the main input power supply to the machine. 2. Remove the case top and side panels with a 3/8” nutdriver. 3. Remove the tool tray wit...
Page 50 - INPUT VOLTAGE; If ALL the voltages tested are incorrect
TROUBLESHOOTING AND REPAIR F-14 F-14 POWER MIG® 215 INPUT VOLTAGE TEST POINTS EXPECTED VOLTAGE READING 11.9-13.0 VAC 14.1-15.2 VAC 16.2-17.5 VAC 18.4-19.7 VAC 20.5-22.0 VAC 22.7-24.2 VAC 24.8-26.5 VAC 26.9-28.8 VAC X1-X2 X1-X3 X1-X4 X1-X5 X1-X6 X1-X7 X1-X8 X9-X10 230 VAC 230 VAC 230 VAC 230 VAC 230 ...
Page 51 - WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST
TROUBLESHOOTING AND REPAIR F-15 F-15 POWER MIG® 215 WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST WARNING Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine o...
Page 55 - OUTPUT BRIDGE RECTIFIER TEST
TROUBLESHOOTING AND REPAIR F-19 F-19 POWER MIG® 215 OUTPUT BRIDGE RECTIFIER TEST Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will invalidate yo...
Page 56 - Front; Negative Lead
TROUBLESHOOTING AND REPAIR F-20 F-20 POWER MIG® 215 OUTPUT BRIDGE RECTIFIER TEST (continued) TEST PROCEDURE 1. Remove input power to the POWER MIG® 215 machine. 2. Using the 3/8” nutdriver, remove the left case side. 3. Locate and disconnect the negative lead from the output rectifier bridge assembl...
Page 57 - This test will determine if the Contactor is functional.; MATERIALS NEEDED
TROUBLESHOOTING AND REPAIR F-21 F-21 POWER MIG® 215 Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will invalidate your factorywarranty. For your ...
Page 58 - Figure F.7. Contactor Terminals and Leads; CONTACTOR TEST
TROUBLESHOOTING AND REPAIR F-22 F-22 POWER MIG® 215 107A 106C 106B OutputContactor Figure F.7. Contactor Terminals and Leads CONTACTOR TEST (Continued) TEST PROCEDURE 1. Remove the input power to the POWER MIG® 215 machine. 2. Using the 5/16” Nutdriver, remove the tool tray. 3. Locate and remove lea...
Page 59 - TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED; Volts; SCOPE SETTINGS
TROUBLESHOOTING AND REPAIR F-23 F-23 POWER MIG® 215 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) 10.0 V 5 ms 0 Volts This is a typical DC output voltage wave-form generated from a properly operat-ing machine. Note that each verticaldivision represents 10 volts and thateach horizont...
Page 60 - NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”)
TROUBLESHOOTING AND REPAIR F-24 F-24 POWER MIG® 215 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”) 20.0 V 1.0 ms 0 Volts This is a typical DC output voltage wave-form generated from a properly operat-ing machine. Note that each verticaldivision represents 20 volts and thateach horizontal divisio...
Page 61 - ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE
TROUBLESHOOTING AND REPAIR F-25 F-25 POWER MIG® 215 ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”) ONE OUTPUT DIODE NOT FUNCTIONING 20.0 V 5 ms 0 Volts This is NOT a typical DC output voltagewaveform. One output diode is not func-tioning. Note the increased ripple con-tent. One diod...
Page 62 - ABNORMAL OPEN CIRCUIT VOLTAGE
TROUBLESHOOTING AND REPAIR F-26 F-26 POWER MIG® 215 ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”) 20.0 V 5 ms 0 Volts This is NOT a typical DC output voltagewaveform. The output capacitors arenot functioning. Note the lack of “filter-ing” in the output waveform. T...
Page 63 - CONTROL BOARD REPLACEMENT; DESCRIPTION
TROUBLESHOOTING AND REPAIR F-27 F-27 POWER MIG® 215 CONTROL BOARD REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will invalidate your ...
Page 64 - PROCEDURE
TROUBLESHOOTING AND REPAIR F-28 F-28 POWER MIG® 215 CONTROL BOARD REPLACEMENT (continued) PROCEDURE 1. Remove power to the machine. 2. Using a 5/16” nutdriver, remove the three screws securing the tool tray. 3. Locate the control board. 4. Disconnect all associated plugs and leads connected to the c...
Page 65 - WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT
F-29 TROUBLESHOOTING AND REPAIR F-29 POWER MIG® 215 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will inva...
Page 66 - Lift cover to gain access to the wire drive.
F-30 TROUBLESHOOTING AND REPAIR F-30 POWER MIG® 215 PROCEDURE 1. Remove power to the machine. 2. Lift cover to gain access to the wire drive. See Figure F.9. 3. Using a pair of pliers, disconnect the gas hose from the bottom of the wire drive.See Figure F.10. 4. Using a 9/16” nut driver, remove the ...
Page 67 - Gas Hose
F-31 TROUBLESHOOTING AND REPAIR F-31 POWER MIG® 215 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued) FIGURE F.10. - WIRE DRIVE HOSE & LEAD LOCATION FIGURE F.11. - MOUNTING SCREW LOCATIONS Gas Hose 9/16" Bolt 5/16" SheetMetal Screws 5/16"Monuting Screws Return to Section T OC Return ...
Page 68 - Place the new wire drive assembly into its
TROUBLESHOOTING AND REPAIR F-32 F-32 POWER MIG® 215 1. Place the new wire drive assembly into its proper position. 2. Connect plug J4. 3. Maneuver assembly back into its original position. 4. Replace all mounting screws previously removed. 5. Using a 3/4” nut driver, replace the thick black lead pre...
Page 69 - OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT
F-33 TROUBLESHOOTING AND REPAIR F-33 POWER MIG® 215 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will ...
Page 71 - FIGURE F.13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET
F-35 TROUBLESHOOTING AND REPAIR F-35 POWER MIG® 215 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) 5/16" Mounting Bracket MountingBolts 1/2" RectifierMounting Bolts MountingBracket FIGURE F.13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET Return to Section T OC Return to Section T...
Page 73 - OUTPUT CAPACITORS REPLACEMENT
F-37 TROUBLESHOOTING AND REPAIR F-37 POWER MIG® 215 OUTPUT CAPACITORS REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will invalidate y...
Page 77 - MAIN TRANSFORMER REPLACEMENT
F-41 TROUBLESHOOTING AND REPAIR F-41 POWER MIG® 215 MAIN TRANSFORMER REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will invalidate yo...
Page 78 - the case wraparound cover.
F-42 TROUBLESHOOTING AND REPAIR F-42 POWER MIG® 215 MAIN TRANSFORMER REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove both sides of the case wraparound cover. 2. Using a 5/16” nutdriver, remove the tool tray. 3. Locate the main transformer. See Figure F.16. 4. Label and disconnect...
Page 79 - REPLACEMENT
F-43 TROUBLESHOOTING AND REPAIR F-43 POWER MIG® 215 MAIN TRANSFORMER REPLACEMENT (Continued) 15. Carefully maneuver the main transformer out the left side of the machine. NOTE: Two people may be needed to maneu-ver the main transformer out of themachine. REPLACEMENT 1. Carefully maneuver the new mai...
Page 83 - FAN BLADE/MOTOR REPLACEMENT
F-47 TROUBLESHOOTING AND REPAIR F-47 POWER MIG® 215 FAN BLADE/MOTOR REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will invalidate you...
Page 84 - Output Capacitor Bank; REAR
F-48 TROUBLESHOOTING AND REPAIR F-48 POWER MIG® 215 FAN BLADE/MOTOR REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side of the case wraparound cover. 2. Perform the Output Capacitor Bank Removal Procedure. 3. Using a 5/16” nutdriver, remove the four fan mounting ...
Page 85 - OUTPUT CONTACTOR REPLACEMENT
F-49 TROUBLESHOOTING AND REPAIR F-49 POWER MIG® 215 OUTPUT CONTACTOR REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unauthorized repairs performed on this equipment may result indanger to the technician or machine operator and will invalidate yo...
Page 88 - RETEST AFTER REPAIR; INPUT IDLE AMPS AND WATTS; Maximum Idle Amps
F-52 TROUBLESHOOTING AND REPAIR F-52 POWER MIG® 215 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS OPEN CIRCUIT VOLTAGE WIRE SPEED RANGE Input Volts/Herts 230/60 Maximum Idle Amps 2.0 Maximum Idle Watts 150 35 - 40 VDC 50 - 700 IPM (1.27 - 17.8 m/minute) Return to Section T OC Return to Section T OC ...
Page 89 - ELECTRICAL DIAGRAMS; TABLE OF CONTENTS
POWER MIG® 215 G-1 ELECTRICAL DIAGRAMS G-1 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM - COMPLETE MACHINE - CODE 11070 - (L11986) ....
Page 90 - ElEcTrical DiaGramS
ElEcTrical DiaGramS G-2 pOWEr miG® 215 WiriNG DiaGram - cOmplETE machiNE - cODE 11070 - (l11986) POWER MIG 215 (208/220/230V) J1 CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) J2 NOTES: N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OFIMMEDIATE AND FUTURE APPL...
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