Lincoln Electric SVM167-A Uživatelský manuál

POWER MIG ®215SERVICE MANUALSVM167-AJanuary, 2011Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safe

INSTALLATIONA-4POWER MIG® 215A-43. The 208/230 volt 50/60 Hz model POWER MIG® isshipped with a 7 ft.(2.1m). input cable and plug con-nected to the we

INSTALLATIONA-5POWER MIG® 215A-5GUN AND CABLE INSTALLATIONThe Magnum 250L gun and cable provided with thePOWER MIG® 215 is factory installed

NOTESA-6A-6POWER MIG® 215Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

TABLE OF CONTENTS- OPERATION SECTION -POWER MIG® 215Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATIONB-2B-2POWER MIG® 215Read entire Operation section beforeoperating the POWER MIG® 215.ELECTRIC SHOCK can kill.• Do not touch electrically

POWER MIG® 215B-3 B-3OPERATIONPRODUCT DESCRIPTIONThe POWER MIG® 215 is a complete semiautomaticDC voltage arc welding machine built to meet NEMAspe

B-4B-4OPERATIONPOWER MIG®PROCEDURE FOR CHANGINGDRIVE AND IDLE ROLL SETS1. Turn off the power source.2. Release the pressure on the idle roll by swingi

OPERATIONB-5B-5POWER MIG® 215FEEDING WIRE ELECTRODEWhen triggering, the electrode anddrive mechanism are electrically “hot”relative to work an

OPERATIONB-6B-6POWER MIG® 2153. Press the trigger to feed the wire electrode throughthe gun and cable. For solid wire cut the electrodewithin approxi

OPERATIONB-7B-7POWER MIG® 2159. When no more welding is to be done, close valveon gas cylinder (if used), momentarily operate guntrigger to release

POWER MIG® 215SAFETYi iFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work re

NOTESB-8B-8POWER MIG® 215Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

TABLE OF CONTENTS- ACCESSORIES SECTION -POWER MIG® 215Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIESC-2C-2POWER MIG® 215DRIVE ROLL KITSRefer to Table C.1 for various drive roll kits that areavailable for the POWER MIG® 215.The i

ACCESSORIESC-3C-3POWER MIG® 215MAKING A WELD WITH THE SPOOL GUNADAPTER KIT AND SPOOL GUNINSTALLED In either toggle switch position, closing either gu

NOTESC-4C-4POWER MIG® 215Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

TABLE OF CONTENTS- MAINTENANCE SECTION -POWER MIG® 215Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCED-2D-2POWER MIG® 215SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Have an electrician install andservice this equipment.• Turn the input pow

MAINTENANCED-3D-3POWER MIG® 215LINER REMOVAL AND REPLACE-MENTNOTE: Changing the liner for a different wire sizerequires replacement of the

MAINTENANCED-4D-4POWER MIG® 215GUN HANDLE DISASSEMBLYThe internal parts of the gun handle may beinspected or serviced if necessary.The gun ha

MAINTENANCED-5D-5POWER MIG® 2156234511. Case Front Assembly2. Rear Panel Assembly3. Center Assembly4. Wire Drive Assembly5. Base & Power Com

SAFETYii iiPOWER MIG® 215FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes

NOTESD-6D-6POWER MIG® 215Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

TABLE OF CONTENTS- THEORY OF OPERATION SECTION -POWER MIG® 215Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THEORY OF OPERATIONE-2E-2POWER MIG® 215FIGURE E.2 – INPUT POWER CIRCUIT.INPUT LINE VOLTAGE, MAINTRANSFORMER, VOLTAGESELECTOR SWITCH ANDB

THEORY OF OPERATIONE-3E-3POWER MIG® 215OUTPUT RECTIFICATION,CONTACTOR AND CONTROLBOARDThe AC voltage developed on the secondarywinding is ap

THEORY OF OPERATIONE-4E-4POWER MIG® 215CONTROL BOARD, GUNTRIGGER AND WIRE DRIVEMOTORWhen the control board receives an activationcommand f

THEORY OF OPERATIONE-5E-5POWER MIG® 215PROTECTIVE DEVICES AND CIRCUITSTHERMAL AND OVERLOAD PROTECTIONThe POWER MIG® 215 has two built-in pro

NOTESE-6E-6POWER MIG® 215Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

TABLE OF CONTENTS- TROUBLESHOOTING AND REPAIR SECTION - POWER MIG® 215Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . .

F-2TROUBLESHOOTING AND REPAIRF-2POWER MIG® 215If for any reason you do not understand the test procedures or are unable to perform thetests/repair

F-3TROUBLESHOOTING AND REPAIRF-3POWER MIG® 215Sometimes machine failures appear to be dueto PC board failures. These problems cansometimes

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinderscontaining the correct shielding gas for theprocess used and properl

OUTPUT PROBLEMSObserve Safety Guidelinesdetailed in the beginning of this manual.Troubleshooting Guide – See Wiring Diagrams for location of specified

When the gun trigger is activatedand the wire feeds normally, butthere is no open circuit voltage.OUTPUT PROBLEMS (Continued)TROUBLESHOOTING

OUTPUT PROBLEMS (Continued)Observe Safety Guidelinesdetailed in the beginning of this manual.Troubleshooting Guide – See Wiring Diagrams for location

TROUBLESHOOTING AND REPAIRObserve Safety Guidelinesdetailed in the beginning of this manual.Troubleshooting Guide – See Wiring Diagrams for location

TROUBLESHOOTING AND REPAIRObserve Safety Guidelinesdetailed in the beginning of this manual.Troubleshooting Guide – See Wiring Diagrams for location

TROUBLESHOOTING AND REPAIRObserve Safety Guidelinesdetailed in the beginning of this manual.Troubleshooting Guide – See Wiring Diagrams for location

TROUBLESHOOTING AND REPAIRObserve Safety Guidelinesdetailed in the beginning of this manual.Troubleshooting Guide – See Wiring Diagrams for location

TROUBLESHOOTING AND REPAIRF-11F-11POWER MIG® 215TEST DESCRIPTIONThis test will determine if the correct voltages are being applied.a. Applied to

TEST PROCEDURETHE ON/OFF POWER SWITCH will be“hot” during these tests.NOTE: Secondary voltages will varyproportionately with the primar

F-13TROUBLESHOOTING AND REPAIRF-13POWER MIG® 215MAIN TRANSFORMER TEST (continued)FIGURE F.2. – LEAD X1FIGURE F.3. – LEAD X9 & X10

SAFETYiv ivPOWER MIG® 215PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté

TROUBLESHOOTING AND REPAIRF-14F-14POWER MIG® 215INPUT VOLTAGE TEST POINTSEXPECTED VOLTAGE READING11.9-13.0 VAC14.1-15.2 VAC16.2-17.5 VAC18.4-19.7

TROUBLESHOOTING AND REPAIRF-15F-15POWER MIG® 215WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TESTWARNINGService and repair should only be

TROUBLESHOOTING AND REPAIRF-16F-16POWER MIG® 215WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST(continued)1. Make the following voltage

TROUBLESHOOTING AND REPAIRF-17F-17POWER MIG® 215WIRE DRIVE MOTOR AND WIRE SPEED POTENTIOMETER TEST(continued)TEST FOR FEEDBACK VOLTAGETO

NOTESF-18F-18POWER MIG® 215Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

TROUBLESHOOTING AND REPAIRF-19F-19POWER MIG® 215OUTPUT BRIDGE RECTIFIER TESTService and repair should only be performed by Lincoln Electric factor

TROUBLESHOOTING AND REPAIRF-20F-20POWER MIG® 215OUTPUT BRIDGE RECTIFIER TEST (continued)TEST PROCEDURE1. Remove input power to the POWERMIG

TROUBLESHOOTING AND REPAIRF-21F-21POWER MIG® 215Service and repair should only be performed by Lincoln Electric factory trainedpersonnel. Unautho

TROUBLESHOOTING AND REPAIRF-22F-22POWER MIG® 215107A106C106B OutputContactorFigure F.7. Contactor Terminals and LeadsCONTACTOR TEST (Continued)TE

TROUBLESHOOTING AND REPAIRF-23F-23POWER MIG® 215TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP “G”)10.0 V 5 ms0 VoltsThis is a typical

vvPOWER MIG® 215MASTER TABLE OF CONTENTS FOR ALL SECTIONSPageSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING AND REPAIRF-24F-24POWER MIG® 215NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”)20.0 V 1.0 ms0 VoltsThis is a typical DC output

TROUBLESHOOTING AND REPAIRF-25F-25POWER MIG® 215ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINELOADED (MAX TAP “G”) ONE OUTPUT DIODE NOT FUNCTIONING20.

TROUBLESHOOTING AND REPAIRF-26F-26POWER MIG® 215ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”)20.0 V 5 ms0 Volt

TROUBLESHOOTING AND REPAIRF-27F-27POWER MIG® 215CONTROL BOARD REPLACEMENTService and repair should only be performed by Lincoln Electric factory

TROUBLESHOOTING AND REPAIRF-28F-28POWER MIG® 215CONTROL BOARD REPLACEMENT (continued)PROCEDURE1. Remove power to the machine.2. Using a 5/1

F-29TROUBLESHOOTING AND REPAIRF-29POWER MIG® 215WIRE DRIVE MOTOR ASSEMBLY REPLACEMENTService and repair should only be performed by Lincoln El

F-30TROUBLESHOOTING AND REPAIRF-30POWER MIG® 215PROCEDURE1. Remove power to the machine.2. Lift cover to gain access to the wire drive.See Figur

F-31TROUBLESHOOTING AND REPAIRF-31POWER MIG® 215WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued)FIGURE F.10. - WIRE DRIVE HOSE &

TROUBLESHOOTING AND REPAIRF-32F-32POWER MIG® 2151. Place the new wire drive assembly into itsproper position. 2. Connect plug J4.3. Man

F-33TROUBLESHOOTING AND REPAIRF-33POWER MIG® 215OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENTService and repair should only be performed by Lincol

TABLE OF CONTENTS- INSTALLATION SECTION -POWER MIG® 215Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F-34TROUBLESHOOTING AND REPAIRF-34POWER MIG® 215OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)PROCEDURE1. Using a 3/8” nutdriver, rem

F-35TROUBLESHOOTING AND REPAIRF-35POWER MIG® 215OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)5/16" Mounting Bracket MountingBolt

F-36NOTESF-36POWER MIG® 215Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

F-37TROUBLESHOOTING AND REPAIRF-37POWER MIG® 215OUTPUT CAPACITORS REPLACEMENTService and repair should only be performed by Lincoln Electric fac

F-38TROUBLESHOOTING AND REPAIRF-38POWER MIG® 215OUTPUT CAPACITORS REPLACEMENT (Continued)PROCEDURE1. Using a 3/8” nutdriver, remove the lower

F-39TROUBLESHOOTING AND REPAIRF-39POWER MIG® 215OUTPUT CAPACITORS REPLACEMENT (Continued)FIGURE F.15. - MOUNTING SCREW/BOLT LOCATIONS}{ 3

F-40NOTESF-40POWER MIG® 215Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

F-41TROUBLESHOOTING AND REPAIRF-41POWER MIG® 215MAIN TRANSFORMER REPLACEMENTService and repair should only be performed by Lincoln Electric fact

F-42TROUBLESHOOTING AND REPAIRF-42POWER MIG® 215MAIN TRANSFORMER REPLACEMENT (Continued)PROCEDURE1. Using a 3/8” nutdriver, remove both sides

F-43TROUBLESHOOTING AND REPAIRF-43POWER MIG® 215MAIN TRANSFORMER REPLACEMENT (Continued)15. Carefully maneuver the main transformerout the

POWER MIG® 215A-2A-2INSTALLATION75°C Copper Wire 75°C Copper WireInput Ampere in Conduit in ConduitInput Voltage/ Fuse or Breaker Rating On AWG (IEC)

F-44TROUBLESHOOTING AND REPAIRF-44POWER MIG® 215MAIN TRANSFORMER REPLACEMENT (Continued)FIGURE F.18. - LEADS SWITCH LEADSFIGURE F.19. -

F-45TROUBLESHOOTING AND REPAIRF-45POWER MIG® 215MAIN TRANSFORMER REPLACEMENT (Continued)5/16" Nut REARACCESS PANELFIGURE F.20. - REAR

F-46NOTESF-46POWER MIG® 215Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

F-47TROUBLESHOOTING AND REPAIRF-47POWER MIG® 215FAN BLADE/MOTOR REPLACEMENTService and repair should only be performed by Lincoln Electric facto

F-48TROUBLESHOOTING AND REPAIRF-48POWER MIG® 215FAN BLADE/MOTOR REPLACEMENT (Continued)PROCEDURE1. Using a 3/8” nutdriver, remove the lo

F-49TROUBLESHOOTING AND REPAIRF-49POWER MIG® 215OUTPUT CONTACTOR REPLACEMENTService and repair should only be performed by Lincoln Electric fact

F-50TROUBLESHOOTING AND REPAIRF-50POWER MIG® 215OUTPUT CONTACTOR REPLACEMENT (Continued)PROCEDURE1. Using a 5/16” nutdriver, remove the

F-51TROUBLESHOOTING AND REPAIRF-51POWER MIG® 215OUTPUT CONTACTOR REPLACEMENT (Continued)7/16" Mounting BoltsFIGURE F.24. - OUTPU

F-52TROUBLESHOOTING AND REPAIRF-52POWER MIG® 215RETEST AFTER REPAIRINPUT IDLE AMPS AND WATTSOPEN CIRCUIT VOLTAGEWIRE SPEED RANGEInput Volts/Hert

POWER MIG® 215G-1ELECTRICAL DIAGRAMSG-1TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION-ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . .

INSTALLATIONA-3POWER MIG® 215A-3Read entire installation section before startinginstallation.SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Only qu

ElEcTrical DiaGramSG-2pOWEr miG® 215WiriNG DiaGram - cOmplETE machiNE - cODE 11070 - (l11986)POWER MIG 215 (208/220/230V)J1CAVITY NUMBERING SEQUENCE

ElEcTrical DiaGramSG-3pOWEr miG® 215WiriNG DiaGram - cOmplETE machiNE - cODE 11099, 11247 - (l12184)POWER MIG 215 (208/220/230V) FOR CODES 11099 AND

ElEcTrical DiaGramSG-4pOWEr miG® 215SchEmaTic - cOmplETE machiNE - cODE 11247 - (l12308 pG1)EN-168SOLIDEDGEL12308ENGINEERING CONTROLLEDMANUFACTURER:

ElEcTrical DiaGramSG-5pOWEr miG® 215SchEmaTic - cOmplETE machiNE - cODE 11247 - (l12308 pG2)EN-168SOLIDEDGEL12308ENGINEERING CONTROLLEDMANUFACTURER:

ElEcTrical DiaGramSG-6pOWEr miG® 215SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11070 - (G3850 pG1)G-6NOTE: This diagram is for reference o

ElEcTrical DiaGramSG-7pOWEr miG® 215SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11070 - (G3850 pG2)G-7NOTE: This diagram is for reference o

ElEcTrical DiaGramSG-8pOWEr miG® 215SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11070 - (G3850 pG3)G-8NOTE: This diagram is for reference o

ElEcTrical DiaGramSG-9pOWEr miG® 215SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11099, 11247 - (G4414 pG1)G-9NOTE: This diagram is for refe

ElEcTrical DiaGramSG-10pOWEr miG® 215SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11099, 11247 - (G4414 pG2)G-10NOTE: This diagram is for re

ElEcTrical DiaGramSG-11pOWEr miG® 215SchEmaTic - cOmmON aNalOG WirEDriVE pc bOarD - cODE 11099, 11247 - (G4414 pG3)G-11NOTE: This diagram is for re