Lincoln Electric 11521 User Manual

POWER MIG® 215XT

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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 READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before you
act and be careful.

SVM209-A

April, 2011

For use with machine code number: 11521

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered 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 engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Power MIG® 215XT

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SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

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.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

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.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

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.

ARC RAYS can burn.

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.

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.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which 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 ven­tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre­cautions are also required when welding on galvanized
steel.

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 expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

vapors

to

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5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

Power MIG® 215XT

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SAFETY

WELDING and CUTTING
SPARKS can cause fire or
explosion.

6.a.
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.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

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.

6.h. Also see item 1.c.

Remove fire hazards from the welding area.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders

If

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.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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Power MIG® 215XT

iv iv

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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a. Utiliser un bon masque avec un verre filtrant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du rayon­nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

Power MIG® 215XT

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

v v

SAFETY

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com­plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national

codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip­ment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

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h) the time of day that welding or other activities are to be carried out.

Power MIG® 215XT

vi vi

SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip­ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip­ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con­nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-

1

tions.

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_________________________

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”

Power MIG® 215XT

I I

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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-580

Power MIG® 215XT

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Uncrating the POWER MIG® 215XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Input Power, Grounding and Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Output Polarity Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Gun and Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

TABLE OF CONTENTS - INSTALLATION SECTION

Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

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Power MIG® 215XT

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS – POWER MIG®215XT

INPUT – SINGLE PHASE ONLY

Standard Voltage/Phase/Frequency

208/230/1/50/60 Hz

Duty Cycle Amps Volts at Rated Amperes

30% 215 Amps 22 Volts
40% 190 Amps 23 Volts
60% 170 Amps 24 Volts

Welding Current Range Maximum Open Circuit Voltage Welding Voltage Range

30 – 250Amps 35 Volts 13.5-24 Volts

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input Voltage/ Fuse or Breaker Rating On AWG (IEC) Sizes AWG (IEC) Sizes

Frequency (Hz) Size (Super Lag) Nameplate (For lengths (For lengths

Input Current @ 170 Amp Rated Output Input Current @ 215 Amp Rated Output

(With 115V receptacle loaded to 15A) (With 115V receptacle loaded to 15A)

39/35 Amps 45/41 Amps

RATED OUTPUT

OUTPUT

75°C Copper Wire 75°C Copper Wire

Input Ampere in Conduit in Conduit

up to 100 ft.) exceeding 100 ft.)

208/50/60 60 45A 10 (6 mm2) 8 (10 mm2)
230/50/60 60 41A 10 (6 mm2) 8 (10 mm2)

NOTE: Use #10 AWG Grounding Wire

WIRE SPEED RANGE

Wire Speed 50 – 700 IPM (1.27 – 17.8 m/minute)

PHYSICAL DIMENSIONS

Height Width Depth Weight

31.79 in 18.88 in 38.78 in 210 Ibs
808 mm 480 mm 985 mm 95 kg

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

-4°F to 104°F(-20°C to +40°C)

STORAGE TEMPERATURE RANGE

-40°F to 185°F(-40°C to +40°C)

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Power MIG® 215XT

A-3 A-3

INSTALLATION

Read entire installation section before starting
installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

• Only personnel that have read
and understood the POWER
MIG® 215XT Operating Manual
should install and operate this
equipment.

• Machine must be grounded per
any national, local or other
applicable electrical codes.

• The Power MIG® power switch is
to be in the OFF position when
installing work cable and gun and
when connecting other equip­ment.

UNCRATING THE POWER MIG®
215XT

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.

INPUT POWER, GROUNDING AND
CONNECTION DIAGRAMS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as
output terminals or internal wiring.

• All input power must be electrically dis­connected before proceeding.

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 volt­age, 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.

2. Models that have multiple input voltages specified
on the nameplate (e.g. 208/230) are shipped con­nected for the highest voltage. If the welder is to be
operated on lower voltage, it must be reconnected
according to the instructions in Figure A.1 for dual
voltage machines.

WARNING

LOCATION

Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
out the front. A location that minimizes the amount of
smoke and dirt drawn into the rear louvers reduces the
chance of dirt accumulation that can block air pas­sages and cause overheating.

Make certain that the input power is electrically
disconnected before removing the screw on the
reconnect panel access cover.

------------------------------------------------------------------------

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Power MIG® 215XT

A-4 A-4

50/60 HZ

INSTALLATION

FIGURE A.1 — Dual Voltage Machine Input Connections

3. The 208/230 volt 50/60 Hz model Power MIG® is
shipped with a 7 ft.(2.1m). input cable and plug con­nected to the welder.

4. Using the instructions in Figure A.2, have a qualified
electrician connect a receptacle (Customer
Supplied) or cable to the input power lines and the
system ground per the U.S. National Electrical
Code and any applicable local codes. See
“Technical Specifications” at the beginning of this
chapter for proper wire sizes. For long runs over
100 feet, larger copper wires should be used. Fuse
the two hot lines with super lag type fuses as shown
in the following diagram. The center contact in the
receptacle is for the grounding connection. A green
wire in the input cable connects this contact to the
frame of the welder. This ensures proper grounding
of the welder frame when the welder plug is insert­ed into a grounded receptacle.

FIGURE A.2 — Receptacle Diagram

CONNECT TO A SYSTEM
GROUNDING WIRE. SEE
THE UNITED STATES
NATIONAL ELECTRICAL
CODE AND/OR LOCAL
CODES FOR OTHER
DETAILS AND MEANS FOR
PROPER GROUNDING.

OUTPUT POLARITY CONNECTIONS

The welder, as shipped from the factory, is connected
for electrode positive (+) polarity. This is the normal
polarity for GMA welding.

If negative (–) polarity is required, interchange the con­nection of the two cables located in the wire drive com­partment near the front panel. The electrode cable,
which is attached to the wire drive, is to be connected
to the negative (–) labeled terminal and the work lead,
which is attached to the work clamp, is to be connect­ed to the positive (+) labeled terminal.

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CONNECT TO HOT WIRES
OF A THREE-WIRE, SINGLE
PHASE SYSTEM.

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Power MIG® 215XT

A-5 A-5

GUN AND CABLE INSTALLATION

The Magnum 250L gun and cable provided with the
POWER MIG® 215XT is factory installed with a liner
for .035-.045" (0.9-1.2 mm) electrode and an .035" (0.9
mm) contact tip. Be sure that the contact tip, liner, and
drive rolls all match the size of the wire being used.

WARNING

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.

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.

Turn the welder power switch off before installing
gun and cable.

1. Lay the cable out straight.

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.

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. Connect the gun trigger connector from the gun and
cable to the mating receptacle inside the compart­ment located above the gun connection made in
item 3 above. Make sure that the keyways are
aligned, insert and tighten retaining ring.

SHIELDING GAS

(For Gas Metal Arc Welding Processes)
Customer must provide cylinder of appropriate type
shielding gas for the process being used.

A gas flow regulator, for Argon blend gas, and an inlet
gas hose are factory provided with the POWER MIG®
215XT. When using 100% CO2an additional adapter
will be required to connect the regulator to the gas bot­tle.

WARNING

CYLINDER may explode if
damaged.

• Gas under pressure is explosive. Always
keep gas cylinders in an upright position
and always keep chained to undercarriage
or stationary support. See American
National Standard Z-49.1, “Safety in
Welding and Cutting” published by the
American Welding Society.

Install shielding gas supply as follows:

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.

WARNING

Be sure to keep your face away from the valve out­let when “cracking” the valve.

4. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench.

NOTE: If connecting to 100% CO2cylinder, an

additional regulator adapter must be
installed between the regulator and cylinder
valve. If adapter is equipped with a plastic
washer, be sure it is seated for connection
to the CO2cylinder.

5. Attach one end of the inlet gas hose to the outlet fit­ting of the flow regulator, the other end to the
POWER MIG® 215XT rear fitting, and tighten the
union nuts securely with a wrench.

6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.

7. Standing to one side, open the cylinder valve slow­ly a fraction of a turn. When the cylinder pressure
gauge pointer stops moving, open the valve fully.

WARNING

Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
stand to one side.

------------------------------------------------------------------------

8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making the weld.

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1. Set gas cylinder on rear platform of POWER MIG®
215XT. Hook chain in place to secure cylinder to
rear of welder.

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AUXILIARY POWER RECEPTACLES

(15 Amp 120 Volt Receptacle) The receptacles are UL
and CSA approved.

Power MIG® 215XT

A-6 A-6

NOTES

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Power MIG® 215XT

B-1 B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Description of Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Wire Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Wire Size Conversion parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

TABLE OF CONTENTS - OPERATION SECTION

Procedure for Changing Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Wire Reel Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Mounting of 10 to 30 lbs. Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

To Start the Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Feeding Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Idle Roll Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Wire Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5, B-6

Making a Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Avoiding Wire Feeding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Input Line Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Wire Feed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Welding Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

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Welding Procedure Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Power MIG® 215XT

B-2 B-2

OPERATION

Read entire Operation section before
operating the POWER MIG® 215XT.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts
or electrode with skin or wet cloth­ing. Insulate yourself from work
and ground.

• Always wear dry insulating
gloves.

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing
zone.

WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

• Do not weld on closed containers.

ARC RAYS can burn eyes and
skin.

• Wear eye, ear and body protec­tion.

Observe all safety information throughout
this manual.

------------------------------------------------------------

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Power MIG® 215XT

B-3 B-3

33

22

11

4

5

OPERATION

PRODUCT DESCRIPTION

The Power MIG® 215XT is a complete semiautomatic
DC voltage arc welding machine built to meet NEMA
specifications. It combines a tapped transformer volt­age power source with a constant speed wire feeder to
form a reliable robust performance welding system. A
simple control scheme, consisting of continuous full
range wire feed speed control, and 7 output voltage tap
selections provides versatility with ease of use and
accuracy. An enhanced feature to the Power MIG®
215XT, is that it is Magnum 100SG Spool Gun ready.

Other features include a 2" (51 mm) O.D. wire reel
spindle with adjustable brake, an integral gas cylinder
mounting undercarriage, an adjustable Argon blend
flow regulator with cylinder pressure gauge and inlet
hose, a 15 ft. (3.6 m) Magnum 250L GMAW gun and
cable with fixed (flush) nozzle, a 7 ft. (2.1 m) power
cable with plug, and a 10 ft. (3.0 m) work cable with
clamp.

Optional Magnum Spool Gun, Push-Pull Guns and
Adapter kits, Dual Cylinder Mounting kit and Aluminum
Feeding Kit for push feeding with standard built in feed­er are also available.

LIMITATIONS

The output voltage/current of the POWER MIG®
215XT is subject to vary if the input power to the
machine varies, due to its tapped transformer power
topology. In some cases an adjustment of WFS preset
and/or voltage tap selection may be required to accom­modate a significant drift in input power.

DESCRIPTION OF CONTROLS

See Figure B.1

1. Power ON/OFF Switch — Place the lever in the

"ON" position to energize the POWER MIG® 215XT.

2. Voltage Control — Seven voltage tap selections

are provided Labeled "A" (minimum voltage)
through "G" (maximum voltage). It should only be
adjusted when not welding. The control selection
can be preset to the setting specified on the
Procedure Decal on the inside of the wire compart­ment door.

3. Wire Speed Control — This controls the wire feed

speed from 50 – 700 inches per minute (1.2 – 17.8
m/min). Wire speed is not affected when changes
are made in the voltage control.

FIGURE B.1

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RECOMMENDED PROCESSES AND
EQUIPMENT

The POWER MIG® 215XT is recommended for GMA
welding processes using 10 to 44 lb (4.5 to 20 kg) 2"
(51 mm) I.D. spools or Readi-Reel®coils (with option­al adapter) of .025" through .045" (0.6 – 1.2 mm) solid
wire, .035" (0.9 mm) stainless, 3/64" (1.2 mm) alu­minum, .035 (0.9 mm), .045" (1.2 mm) Outershield
and .045”(1.2mm) Ultracore® as well as .035" (0.9
mm) and .045" (1.2 mm) Innershield®self-shielding
electrodes.

The Power MIG® is factory equipped to feed .035" (0.9
mm) electrodes. It also includes a 200A, 60% duty
cycle (or 250A, 40% duty cycle) rated, 15 ft. (3.6 m)
GMAW gun and cable assembly equipped for these
wire sizes. Use of GMAW processes requires a supply
of shielding gas.

WELDING CAPABILITY

The POWER MIG® 215XT is rated at 215 amps @ 22
volts, at a 30% duty cycle based on a ten minute cycle
time. It is capable of higher duty cycles at lower output
currents. The tapped transformer design makes it well
suited for use with most portable or in-plant generating
systems.

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®

4. Magnum Push Gun and spool gun toggle switch-

Toggle the switch to select between push gun and
spool gun. When spool gun operation is selected,
insert the cable to 4-pin Connector Item 5. (See
Figure B.1a)

5. 4-Pin Connector-For Spool Gun Operation.
FIGURE B.1a

Power MIG® 215XT

B-4 B-4

2 IN, O.D. SPINDLE

ADAPTER

RELEASE
BAR

INSIDE CAGE WIRES

READI-REEL

GROOVES

BRAKE
HOLDING
PIN

RETAINING
COLLAR

RETAINING SPRING

LOCKED POSITION

UNLOCKED POSITION

WIRE DRIVE ROLL

OPERATION

1. Open the Wire Drive Compartment Door

2. Depress the Release Bar on the Retaining Collar and

The drive rolls installed with the POWER MIG® 215XT
have two grooves one for .035(0.9mm) wire and the
other for .045(1.2mm) wire. Drive roll size is indicated
by the stenciling on the exposed side of the drive roll.

remove it from the spindle.

3. Place the Optional Adapter on the spindle

4. Re-install the Retaining Collar. Make sure that the

Release Bar “pops up” and that the collar retainers fully
engage the retaining ring groove on the spindle.

5. Rotate the spindle and adapter so the retaining spring is

WIRE SIZE CONVERSION PARTS

at the 12 o'clock position.

6. Position the Readi-Reel so that it will rotate in a direction

The POWER MIG® 215XT is rated to feed .025
through .045" (0.6-1.2 mm) solid or cored electrode
sizes.

when feeding so as to be de- reeled from top of the coil.

7. Set one of the Readi-Reel inside cage wires on the slot in

the retaining spring tab.

8. Lower the Readi-Reel to depress the retaining spring and

The drive roll kits and Magnum 250L gun and cable
parts are available to feed different sizes and types of
electrodes. See Accessories section.

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.

PROCEDURE FOR CHANGING
DRIVE 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 of
the machine. Lift the cast idle roll assembly and
allow it to sit in an upright position..

3. Remove the outside wire guide retaining plate by
loosening the two large knurled screws.

4. Twist the drive roll retaining mechanism to the

unlocked position as shown below and remove the
drive rolls. (See Figure B.2)

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.

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.

WIRE REEL LOADING - READI-REELS,
SPOOLS OR COILS

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To Mount a 30 Lb. (14 kg) Readi-Reel Package
(Using the Molded Plastic K363-P Readi-Reel
Adapter:)

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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.

-----------------------------------------------------------------------------------------------

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.

To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300 mm
Diameter) or 14Lb.(6 Kg) Innershield Coils:

(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil Adapter must be
used).

1

. Open the Wire Drive Compartment Door

2. Depress the Release Bar on the Retaining Collar and

remove it from the spindle.

3. Place the spool on the spindle making certain the spindle

brake pin enters one of the holes in the back side of the
spool (Note: an arrow mark on the spindle lines up with
the brake holding pin to assist in lining up a hole). Be cer­tain the wire comes off the reel in a direction so as to de­reel from the top of the coil.

4. Re-install the Retaining Collar. Make sure that the

Release Bar “pops up” and that the collar retainers fully
engage the retaining ring groove on the spindle.

Power MIG® 215XT

CAUTION

FIGURE B.1

B-5 B-5

ALUMINUM

OU TE R S HI E L D

METAL SHI ELD
INNE RS HI EL D

STEEL

STAIN L ESS

C O R E D W I R E S

SOLID WIRES

6

1
3

2

5

4

TO START THE WELDER

Turn the “Power Switch” switch to “ON”. With the desired voltage
and wire speed selected, operate the gun trigger for welder output
and to energize the wire feed motor.

OPERATION

The pressure arm controls the amount of force the drive
rolls exert on the wire. Proper adjustment of both pressure
arm gives the best welding performance. For best results,
set both pressure arms to the same value.

FEEDING WIRE ELECTRODE

WARNING

When triggering, the electrode and
drive mechanism are electrically “hot”
relative to work and ground and
remain “hot” several seconds after
the gun trigger is released.

------------------------------------------------------------------------

NOTE: Check that drive rolls, guide plates and gun

parts are proper for the wire size and type
being used. Refer to Table C.1 in Accessories
section.

1. Turn the Readi-Reel or spool until the free end of the
electrode is accessible.

2. While securely holding the electrode, cut off the bent
end and straighten the first six inches. (If the elec­trode is not properly straightened, it may not feed
properly through the wire drive system).

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 suf­ficient wire length to assure that the wire has fed into
the gun and cable assembly without restriction.
Reposition the adjustable pressure arm to its origi­nal position to apply pressure to the wire.

4. Press gun trigger to feed the electrode wire through
the gun.

IDLE ROLL PRESSURE SETTING

WARNING

Set the pressure arm as follows (See Figure B.2a):

Aluminum wires between 1 and 3
Cored wires between 3 and 4
Steel, Stainless wires between 4 and 6

FIGURE B.2a

WIRE DRIVE CONFIGURATION

(See Figure B.2b)

Changing the Gun Receiver Bushing

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding
power source before installation or
changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground
and could remain energized several seconds
after the gun trigger is released.

• Only qualified personnel should perform mainte­nance work.

-----------------------------------------------------------------------

Tools required:

• 1/4" hex key wrench.

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ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding
power source before installation or
changing drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and
drive mechanism are "hot" to work and ground
and could remain energized several seconds
after the gun trigger is released.

• Only qualified personnel should perform mainte­nance work.

------------------------------------------------------------------------

Power MIG® 215XT

NOTE: Some gun bushings do not require the use of

the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

B-6 B-6

GUN RECEIVER BUSHING

LOOSEN TIGHTEN

THUMB SCREW

OUTER WIRE GUIDE

SOCKET HEAD
CAP SCREW

CONNECTOR BLOCK

5. Loosen the socket head cap screw that holds the

connector bar against the gun bushing.

Important: Do not attempt to completely

remove the socket head cap screw.

OPERATION

3. Press the trigger to feed the wire electrode through
the gun and cable. For solid wire cut the electrode
within approximately 3/8" (10 mm) of the end of the
contact tip [3/4" (20 mm) for Outershield®].

6. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the pre­cision fit, light tapping may be required to remove
the gun bushing.

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.

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.

10. Tighten the socket head cap screw.

11. Insert the welding gun into the gun bushing and
tighten the thumb screw.

MAKING A WELD

1. Check that the electrode polarity is correct for the

process being used, then turn the power switch
ON.

2. Set desired arc voltage tap and wire speed for the

particular electrode wire, material type and thick­ness, 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

4. When welding with gas, turn on the gas supply and
set the required flow rate (typically 25-35 CFH; 12­16 liters/min).

5. Connect work cable to metal to be welded. Work
clamp must make good electrical contact to the
work. The work must also be grounded as stated in
“Arc Welding Safety Precautions”.

WARNING

• When using an open arc process, it
is necessary to use correct eye,
head, and body protection.

-----------------------------------------------------------------------

6. Position electrode over joint. End of electrode may
be lightly touching the work.

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
Outershield®].

8. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.

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Power MIG® 215XT

B-7 B-7

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

NOTE: When using Innershield electrode, the gas

nozzle may be removed from the insulation on
the end of the gun and replaced with the gas­less nozzle. This will give improved visibility
and eliminate the possibility of the gas nozzle
overheating.

AVOIDING WIRE FEEDING
PROBLEMS

Wire feeding problems can be avoided by observing
the following gun handling procedures:

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.

4. Keep cable clean by following maintenance instruc-

tions.

5. Use only clean, rust-free electrode. The Lincoln

electrodes have proper surface lubrication.

6. Replace contact tip when the arc starts to become

unstable or the contact tip end is fused or deformed.

7. Keep wire reel spindle brake tension to minimum

required to prevent excess reel over-travel which
may cause wire “loop-offs” from coil.

8. Use proper drive rolls and wire drive idle roll pres-

sure for wire size and type being used.

FAN CONTROL

The fan is designed to come on when input power is
applied to the POWER MIG® 215XT and go off when
power is removed.

OPERATION

INPUT LINE VOLTAGE VARIATIONS

High Line Voltage — Higher than rated input voltage

will result in output voltages higher than normal for a
given tap setting. If your input line is high, you may
want to select a lower voltage tap than given on the
recommended procedure chart.

Low Line Voltage — You may not be able to get max­imum 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 high­er voltage tap than given on the recommended proce­dure chart.

WIRE FEED OVERLOAD
PROTECTION

The POWER MIG® 215XT has solid state overload
protection of the wire drive motor. If the motor becomes
overloaded, the protection circuitry turns off the wire
feed speed and gas solenoid. Check for proper size tip,
liner, and drive rolls, for any obstructions or bends in
the gun cable, and any other factors that would impede
the wire feeding. to resume welding, simply pull the
trigger. There is no circuit breaker to reset, as the pro­tection is done with reliable solid state electronics.

WELDING THERMAL OVERLOAD
PROTECTION

The POWER MIG® 215XT has built-in protective ther­mostats that respond to excessive temperature. They
open the wire feed and welder output circuits if the
machine exceeds the maximum safe operating tem­perature because of a frequent overload, or high ambi­ent temperature plus overload. The thermostats auto­matically reset when the temperature reaches a safe
operating level and welding and feeding are allowed
again, when gun is retriggered.

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PROCEDURE CHART

Wire Feed Speed/Voltage Tap Settings

Wire Dia. Gas Type Wire Type

Outershield

.035 75Ar/25CO2OS71M DC+

.035 100%CO2OS71M DC+

.045 75Ar/25CO2OS71M DC+

Innershield

.035 NoneReq’d NR-211MP DC­.045 NoneReq’d NR-211MP DC­.045 NoneReq’d NR212 DC-

†

Contact Tip to Work Distance
* Note- Requires Multiple Pass
**.035 & .045 NR-211 MP are only recommended for a maximum steel thickness of 5/16"

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1" CTWD

5/8" CTWD

†

†

Polarity 18 gage 16 gage14 gage 12 gage10gage 3/16 1/4 5/16 3/8 1/2

50/B 70/B 80/B 90/C 100/C

40/B 50/B 60/B 65/C 70/C 90/C 110/D

Power MIG® 215XT

250/D 300/E 350/F 500/G *500/G

300/E 350/F 500/G

200/E 225/F 250/G 250/G *250/G

50/B 70/C 90/C 110/D

**130/E

*130/E *150/E *150/E

B-8 B-8

NOTES

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Power MIG® 215XT

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Aluminum Feeding Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

K363P Readi-Reel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Dual Cylinder Mounting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Alternative Magnum GMAW Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Magnum Gun Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Optional Spool Guns and Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Magnum 250XL Push-Pull Gun and Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3

TABLE OF CONTENTS - ACCESSORIES SECTION

Connecting The Magnum 250lx Push-Pull Gun and Magnum 250LX Push-Pull Gun Adapter . . . . . . . . . .C-3

Make a Weld with the Magnum 250LX Push-Pull Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3

Making a Weld with the Spool Gun Adapter Kit and Spool Gun Installed . . . . . . . . . . . . . . . . . . . . . . . . . .C-4

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Power MIG® 215XT

C-2 C-2

ACCESSORIES

DRIVE ROLL KITS

Refer to Table C.1 for various drive roll kits that are
available for the POWER MIG® 215XT. The item in
Bold is supplied standard with the POWER MIG®
215XT.

TABLE C.1

Wire Size Drive Roll Kit

Solid
Steel

Cored

Aluminum

.023”-.030” (0.6-0.8 mm)

.035” (0.9 mm) KP1696-035S
.045” (1.2 mm) KP1696-045S

.035-.045 (0.9-1.2mm) KP1696-1

.040 (1.01) KP1696-2

.035” (0.9 mm) KP1697-035C
.045” (1.2 mm) KP1697-045C

3/64” (1.2 mm) KP1695-3/64A

KP1696-030S

3/64" (1.2 mm) ALUMINUM
FEEDING KIT (K1703-1)

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.

ALTERNATIVE MAGNUM GMAW
GUN AND CABLE ASSEMBLIES

The following Magnum 250L gun and cable assemblies
are separately available for use with the POWER
MIG® 215XT. Each is rated 250 amps 40% duty cycle
and is equipped with the integrated connector, twist­lock trigger connector, fixed nozzle and insulator, and
includes a liner, diffuser, and contact tips for the wire
sizes specified:

English Wire Metric Wire

Length Part No. Size Size

10' (3.0 m) K533-1
12' (3.6 m) K533-7 .035 – .045" 0.9 – 1.2 mm
15' (4.5 m) K533-3

WARNING

• Unplug or Disconnect all input
power from the POWER MIG® 215XT
before installing the Spool Gun and
Kit.

------------------------------------------------------------------------

MAGNUM GUN CONNECTION KIT
(Optional K466-6)

Using the optional K466-6 Magnum Connection kit for
the POWER MIG® 215XT permits use of standard
Magnum 200, 300 or 400 gun and cable assemblies.

Kit includes drive rolls and wire guide plate for the wire
drive, liner and two contact tips for the gun, along with
installation instructions.

READI-REEL ADAPTER (K363P)

The K363P Readi-Reel Adapter mounts to the 2" spin­dle. It is needed to mount the 22-30 lb. Readi-Reels.

DUAL CYLINDER MOUNTING KIT
(K1702-1)

Permits stable side-by-side mounting of two full size

228.6mm dia x 1.524m high(9" dia. x 5' high) gas cylin­ders with “no lift” loading. Simple installation and easy
instructions provided. Includes upper and lower cylin­der supports, wheel axles and mounting hardware.

SMALL SPOOL SPINDLE ADAPTER
(K468)

The K468 spindle adapter allows the use of 8" diame­ter small spools.

OPTIONAL SPOOL GUNS AND
ADAPTERS

The Power MIG® 215XT is capable of operating with the fol­lowing optional spool guns:

SPOOL GUN

Magnum 100SG

(K2532-1)

Magnum SG

(K487-25)

Magnum 250LX

(K2490-1)

Spool gun Adapter (K2703-1)

This kit is designed to allow the Magnum SG or Magnum
250LX spool gun to operate with the Power MIG® 215XT.
The kit includes the solenoid, gas lines, wiring harness and
gun connection panel. The gun connection panel features a
6 pin ms-type connector for the Magnum SG spool gun and
a 7 pin ms-type connector for the Magnum 250LX spool gun
and a selector switch to choose which gun you are using.

Note the K2703-1 spool gun adapter disables the
Magnum 100SG capability.

300 Amp 60% Duty Cycle

RATING

Light Duty

130amp 30% Duty Cycle

Medium Duty

250Amp 60% Duty Cycle

Heavy Duty

ADAPTER

Factory Capable

No Adapter Required

Spool Gun Adapter

K2703-1

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Power MIG® 215XT

C-3 C-3

PLUG INTO
AVAILABLE 120VAC
POWER SOURCE

7-PIN
CABLE
CONNECTORS

4-PIN
CABLE
CONNECTOR

MAGNUM 250LX
PUSH-PULL GUN

ADAPTER

ACCESSORIES

MAGNUM 250LX PUSH-PULL GUN
AND PUSH PULL ADAPTER

For heavier duty aluminum applications when use of large
16 pound aluminum spools of wire are desired the follow­ing push pull gun and adapter kit are available.

Magnum 250LX Push Pull Gun (K2704-1)

This pistol grip push pull gun is similar to the Magnum
250LX spool gun except it is designed to feed large
spools of wire. The Magnum 250LX push pull features a
25 foot power, gas and control cable. It operates as an
assist slave motor pulling the aluminum wire as the Power
MIG® drive motor acts as the master push motor.

Magnum 250LX Push Pull Adapter (K2705-1)

This adapter box is designed to drive the Magnum 250LX
push pull gun when used on a non push ready Lincoln
power source feeder such as the Power MIG® 215XT or
255XT. This box features a 115V cord and plug to power
the box, a control cable with receptacle to connect the
push pull gun’s control cable to, and a 4-pin connector to
connect to the Power MIG® gun trigger receptacle.

Note the Magnum 250LX push pull gun has a wire feed
speed adjustment potentiometer. However this poten­tiometer only functions on push-pull ready machines like
the Power MIG® 350MP. When the Magnum 250LX is
used on a non-push-pull machine with the K2705-1
adapter, the wire feed speed is set on the control panel of
the machine.

CONNECTING THE MAGNUM 250LX
PUSH-PULL GUN (K2704-1) AND
MAGNUM 250LX PUSH-PULL GUN
ADAPTER (K2705-1)

FIGURE C.1

See Figure C.1

1. Plug the 115 VAC cable into available 115V AC recep-

tacle. The Power MIG®215XT (K2701-1) furnishes
the 15A 115V AC auxiliary supply. The receptacle is
located at the back of the machine.

2. Connect the 4-pin connector cable of the Push-Pull
Gun Adapter to the 4-pin trigger receptacle located in
the front section of the wire drive compartment.

3. Connect the 7-pin connector cable of the Push-Pull
Gun to the 7-pin receptacle cable from the adapter.

4. Connect the Push-Pull gas & power pin into the Power

MIG®wire feeder brass bushing.

5. Attach a gas hose from the Gas supply to the rear inlet

gas fitting on the Power MIG®215XT

MAKE A WELD WITH THE MAGNUM
250LX PUSH-PULL GUN

1. Power MIG®215XT

a. Set machine to non spool gun operation.

b. Turn the Power MIG®215XT input power ON.
c. Adjust the voltage control at the front panel.
d. Adjust the wire speed control on the front panel.

Refer to the procedure decal mounted at the inside
of the wire feeder compartment cover.

2. Magnum 250LX Push-Pull Gun:
a. Set machine to non spool gun operation.
b. Closing Push-Pull gun trigger starts the Push-Pull

gun welding and makes all guns connected to the
machine electrically “Hot”.

c. The Push-Pull Adapter will provide power and con-

trol to the “Pull” motor of the Push-Pull gun & the

Power MIG®215XT will control its wire drive.

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Power MIG® 215XT

C-4 C-4

ACCESSORIES

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 “HOT”. Be sure unused gun is posi­tioned so electrode or tip will not contact metal
case or other metal common to work.

-----------------------------------------------------------------------

1. Setting spool gun selector switch to the “Normal”
position and pulling the trigger for the built-in feed­er gun.

• Disables spool gun operation and spool gun gas

solenoid valve.

• Closing feeder gun trigger starts feeder gun

welding and makes both electrodes electrically
“HOT”.

2. Setting spool gun selector switch to the Spool Gun
Position, select either spool gun and pulling
SPOOL GUN Trigger.

4. Refer to the procedure decal on the Power MIG®
for initial aluminum settings. Make a test weld to
determine the final settings.

5. To return to normal POWER MIG® 215XT welding,
release the spool gun trigger set spool gun selector
switch to normal and reset feeder gun voltage pro­cedure setting if necessary.

• 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 weld­ing and makes both electrodes electrically
“HOT”.

3. Operation with POWER MIG® 215XT:

• Turn the POWER MIG® 215XT input power ON.

• Adjusting the voltage tap control will increase or
decrease your welding voltage.

• Adjusting the wire speed control on the spool
gun will increase or decrease the spool gun wire
feed speed.
NOTE: Adjusting the wire feed speed control on

the Power MIG® Panel has no affect on
the spool gun’s wire feed speed.

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Power MIG® 215XT

D-1 D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Drive Rolls and guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Contact Tip and Gas Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Gun Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Liner Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Gun Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

TABLE OF CONTENTS - MAINTENANCE SECTION

Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5

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Power MIG® 215XT

D-2 D-2

SAFETY PRECAUTIONS

MAINTENANCE

• Be sure the nozzle insulator is fully screwed
onto the gun tube and does not block the gas
holes in the diffuser.

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and
service this equipment.

• Turn the input power off at the
fuse box before working on
equipment

• Do not touch electrically hot
parts.

GENERAL MAINTENANCE

• 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.

• Adjust the gas nozzle as appropriate for the
GMAW process to be used. Typically, the con­tact 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.

In extremely dusty locations, dirt may clog the air pas­sages 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.

The fan motors have sealed ball bearings which
require no service.

DRIVE ROLLS AND GUIDE PLATES

After every coil of wire, inspect the wire drive mecha­nism. Clean it as necessary by blowing with low pres­sure 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.

For instructions on replacing or changing drive roll,
see Wire Drive Rolls in Operation section.

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.

GUN TUBES AND NOZZLES

1. Replace worn contact tips as required.

2. Remove spatter from inside of gas nozzle and from
tip after each 10 minutes of arc time or as required.

GUN CABLE CLEANING

To help prevent feeding problems, clean cable liner
after using approximately 300 pounds (136 kg) of elec­trode. 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.

WARNING

Excessive pressure at the beginning of the clean­ing 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.

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2. Screw the appropriate fixed gas nozzle fully onto
the diffuser. Either the standard .50" (12.7 mm)
flush nozzle or other optional flush or recessed
(spray arc) nozzle sizes may be used. (See Table
D.2 in this section.)

3. If using optional adjustable slip-on nozzles, See
Table D.2 in this section.

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Power MIG® 215XT

D-3 D-3

SET SCREW

SET SCREW

BRASS CABLE CONNECTOR

GAS DIFFUSER

NOZZLE INSULATOR (IF USED)

GAS NOZZLE

1-1/4"

(31.8mm)

LINER

TRIM

LENGTH

LINER REMOVAL AND REPLACE­MENT

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

Replacement Size Stencilled Gas Diffuser Gas Diffuser
Diameter of Liner Part on End of Part No. Part No.
Electrodes Used Number Liner Bushing (and Stencil) and Stencil)

.025-.030" Steel KP1934-2 .030 (0.8 mm) KP2026-3 KP2026-2

(0.6-0.8 mm)

.035-.045" Steel KP1934-1 .045 (1.2 mm) KP2026-3 KP2026-2

(0.9-1.2 mm)

3/64" Aluminum KP1955-1 3/64" (1.2 mm) KP2026-3 KP2026-2

(1.2 mm)

MAINTENANCE

7. Screw the gas diffuser onto the end of the gun tube
and securely tighten. Be sure the gas diffuser is cor­rect for the liner being used. (See table and diffuser
stencil.)

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.

Fixed Adjustable

Nozzle Nozzle

FIGURE D.1

LINER REMOVAL, INSTALLATION AND TRIMMING
INSTRUCTIONS FOR
MAGNUM 250L

NOTE: The variation in cable lengths prevents the

1. Remove the gas nozzle and nozzle insulator, if

2. Remove the gas diffuser from the gun tube.

3. Lay the gun and cable out straight on a flat surface.

4. Insert a new untrimmed liner into the connector end

5. Fully seat the liner bushing into the connector. tight-

6. With the gas diffuser still removed from the gun

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Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

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.

Loosen the set screw located in the brass connec­tor at the feeder end of the cable and pull the liner
out of the cable.

of the cable. Be sure the liner bushing is stencilled
appropriately for the wire size bing used.

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.

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.

Power MIG® 215XT

CAUTION

This screw should only be gently tightened.
Overtightening will split or collapse the liner and
cause poor wire feeding.

D-4 D-4

GUN HANDLE DISASSEMBLY

MAINTENANCE

TABLE D.2

ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS

The internal parts of the gun handle may be
inspected or serviced if necessary.

The gun handle consists of two halves that
are held together with a collar on each end.
To open up the handle, turn the collars
approximately 60 degrees counterclockwise
(the same direction as removing a right hand
thread) until the collar reaches a stop. Then
pull the collar off the gun handle. If the collars
are difficult to turn, position the gun handle
against a corner, place a screwdriver against
the tab on the collar and give the screwdriver
a sharp blow to turn the collar past an internal
locking rib.

FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES

English Metric

Description Part No. Size Size

CABLE LINER
For 15' (4.5 m) or KP1934-2 .025 – .030" 0.6 – 0.8 mm

shorter Cable KP1934-1 .035 – .045" 0.9 – 1.2 mm

KP1955-1 3/64" 1.2 mm

(Alum. wire) (Alum. wire)

CONTACT TIPS
Standard Duty KP2020-6B1 .025" 0.6 mm

KP2020-7B1 .030" 0.8 mm
KP2020-1B1* .035" 0.9 mm
KP2020-2B1 .045" 1.2 mm

Heavy Duty KP2021-1B1 .035" 0.9 mm

KP2020-2B1 .045" 1.2 mm

Tapered KP2022-5B1 .025" 0.6 mm

KP2022-6B1 .030" 0.8 mm
KP2022-1B1 .035" 0.9 mm
KP2022-2B1 .045" 1.2 mm

Tab (For Aluminum) KP2010-5B1 3/64" 1.2 mm

(Alum. Wire) (Alum. Wire)

Counterclockwise



GAS NOZZLES
Fixed (Flush) KP1931-1 3/8" 9.5 mm

KP1931-2 * 1/2" 12.7 mm
KP1931-3 5/8" 15.9 mm

Fixed (Recessed) KP1930-1 3/8" 9.5 mm

KP1930-2 1/2" 12.7 mm

KP1930-3 5/8" 15.9 mm
Requires: Gas
Diffuser As'bly KP2026-3 * .025 – .045" 0.6 – 1.2 mm

Adjustable Slip-On KP1935-2 1/2" 12.7 mm

KP1935-1 5/8" 15.9 mm
Requires:
Nozzle Insulator KP2025-1
As’bly

Requires:
Gas Diffuser KP2026-2 .025 – .030" 0.6 – 0.8 mm
As’bly KP2026-1 .035 – .045" 0.9 – 1.2 mm

Gasless Nozzle KP1947-1 ∆

(For Innershield)

GUN TUBE ASSEMBLIES

Standard (60°) KP2015-1 *
45° KP2041-1

* Included with POWER MIG® 215XT
∆ Requires KP2026-1 Gas Diffuser Assembly.

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Power MIG® 215XT

D-5 D-5

66

22

33

44

55

11

FIGURE D.2 - MAJOR COMPONENT LOCATIONS

1. Case Front Assembly

2. Rear Panel Assembly

3. Center Assembly

4. Wire Drive Assembly

5. Base & Power Component Assembly

6. Covers Assembly

MAINTENANCE

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Power MIG® 215XT

D-6 D-6

NOTES

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Power MIG® 215XT

E-1 E-1

LINE
SWITCH

RECONNECT
PANEL

FAN
MOTOR

CONTROL BOARD

GAS
SOLENOID

WIRE
SPEED
CONTROL

SPOOL

GUN

SWITCH

WIRE
DRIVE
MOTOR

TACH

FEEDBACK

GUN TRIGGE R

+

-

OUTPUT DIODE
BRIDGE

+

-

NEGATIVE
TERMINA L

CONTACTOR

CONTACTOR

CONTROL

TAP SELECTOR
SWITCH

OUTPUT
CHOKE

POSITIVE
TERMINAL

TRANSFORMER
THERMOSTAT

OUTPUT BRIDGE
THERMOSTAT

MAIN
TRANSFOR MER

OUTPUT
CAPACITORS

GUN
ASSEMBLY

115V

RECEPTACLE

CIRCUIT

BREAKER

27.8 V
AC

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Input Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Voltage Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Baffle Mounted Diode Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Output Rectification, Contactor & Control Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Optional Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Control Board, Gun Trigger, & Wire Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Protective Devices & Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

Thermal Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

Wirefeed Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

FIGURE E.1 BLOCK LOGIC DIAGRAM

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Power MIG® 215XT

E-2 E-2

LINE
SWITCH

RECONNECT
PANEL

FAN
MOTOR

CONTROL BOARD

GAS
SOLENOID

WIRE
SPEED
CONTROL

SPOOL

GUN

SWITCH

WIRE
DRIVE
MOTOR

TACH

FEEDBACK

GUN TRIGGE R

+

-

OUTPUT DIODE
BRIDGE

+

-

NEGATIVE
TERMINA L

CONTACTOR

CONTACTOR

CONTROL

TAP SELECTOR
SWITCH

OUTPUT
CHOKE

POSITIVE
TERMINAL

TRANSFORMER
THERMOSTAT

OUTPUT BRIDGE
THERMOSTAT

MAIN
TRANSFORMER

OUTPUT
CAPACITORS

GUN
ASSEMBLY

115V

RECEPTACLE

CIRCUIT

BREAKER

27.8 V
AC

THEORY OF OPERATION

FIGURE E.2 - INPUT POWER CIRCUIT

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INPUT LINE VOLTAGE, MAIN
TRANSFORMER, VOLTAGE
SELECTOR SWITCH AND BAFFLE
MOUNTED DIODE BRIDGE

The single phase input power is connected to the
Power MIG® 215XT through a line switch located on
the front panel.

A reconnect panel allows the user to configure the
machine for the desired input voltage. The AC input
volt a g e is applied to t h e p r i m a r y of the main
tr a n s f o r m e r. The cooling fan mo t o r and 115v
receptacle (115VAC) is powered from a portion of the
secondary winding. For welding purposes, the main
transformer converts the high voltage, low current
input power to a low voltage, high current output. This
tapped secondary winding is coupled to a voltage
selector switch. By selecting one of seven positions
on the switch the user can preset the desired voltage
output from a minimum setting (A) to a maximum
voltage setting (G).

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Power MIG® 215XT

E-3 E-3

LINE
SWITCH

RECONNECT
PANEL

FAN
MOTOR

CONTROL BOARD

GAS
SOLENOID

WIRE
SPEED
CONTROL

SPOOL

GUN

SWITCH

WIRE
DRIVE
MOTOR

TACH

FEEDBACK

GUN TRIGGE R

+

-

OUTPUT DIODE
BRIDGE

+

-

NEGATIVE
TERMINA L

CONTACTOR

CONTACTOR

CONTROL

TAP SELECTOR
SWITCH

OUTPUT
CHOKE

POSITIVE
TERMINAL

TRANSFORMER
THERMOSTAT

OUTPUT BRIDGE
THERMOSTAT

MAIN
TRANSFORMER

OUTPUT
CAPACITORS

GUN
ASSEMBLY

115V

RECEPTACLE

CIRCUIT

BREAKER

27.8 V
AC

THEORY OF OPERATION

FIGURE E.2 - CONTROL CIRCUITS

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OUTPUT RECTIFICATION, CONTACTOR
AND CONTROL BOARD

The AC voltage developed on the secondary winding
is applied, through the selector switch and output
contactor, to the output rectifier bridge. This DC
welding voltage is filtered by the output capacitors and
applied to the output terminals and welding gun. Since
the output choke is in series with the positive leg of
the output rectifier and also in series with the gun and
welding load, a filtered constant voltage output is
applied to the output terminals of the machine.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

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Power MIG® 215XT

E-4 E-4

LINE
SWITCH

RECONNECT
PANEL

FAN
MOTOR

CONTROL BOARD

GAS
SOLENOID

WIRE
SPEED
CONTROL

SPOOL

GUN

SWITCH

WIRE
DRIVE
MOTOR

TACH

FEEDBACK

GUN TRIGGE R

+

-

OUTPUT DIODE
BRIDGE

+

-

NEGATIVE
TERMINA L

CONTACTOR

CONTACTOR

CONTROL

TAP SELECTOR
SWITCH

OUTPUT
CHOKE

POSITIVE
TERMINAL

TRANSFORMER
THERMOSTAT

OUTPUT BRIDGE
THERMOSTAT

MAIN
TRANSFORMER

OUTPUT
CAPACITORS

GUN
ASSEMBLY

115V

RECEPTACLE

CIRCUIT

BREAKER

27.8 V
AC

THEORY OF OPERATION

FIGURE E.2 - OPTIONAL CIRCUITS

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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
outp u t contactor. It also su p p l i e s 2 to 29 VD C
(depending on the wire speed setting) to the wire drive
motor. The control board monitors the motor’s tach
feedback signals and compares these to the wire
speed control setting. The proper armature voltage is
then applied to the wire drive motor. The drive motor
speed is thus controlled which in turn regulates the
electrode wire feed speed through the gun.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

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Power MIG® 215XT

Two self re-setting thermostats are included in the
trigger circuitry. If either of these thermostats would
“open” due to excessive heat, the trigger circuit would
be interrupted and the machine’s output and the wire
feed would be disabled. The board also contains
overload protection circuitry which protects the drive
motor from excessive current draw.

The Power MIG® 215XT is equipped with an adapter
panel and switch to allow operation of a spool gun for
feeding aluminum wires.

E-5 E-5

THEORY OF OPERATION

PROTECTIVE DEVICES AND CIRCUITS

THERMAL AND OVERLOAD PROTECTION

The Power MIG® 215XT has two built-in protective
thermostats that respond to excessive temperatures.
One is located on the main transformer. The other
thermostat is located on the output rectifier heat sink
assembly. They open the wire feed and welder
output circuits if the machine exceeds the maximum
safe operating temperature. This can be caused by
a frequent overload or high ambient temperature.

The 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.

WIREFEED OVERLOAD PROTECTION

The Power MIG® 215XT has solid state overload
protection of the wire drive motor. If the motor
becomes overloaded, the protection circuitry turns off
the wire feed speed and gas solenoid. Check for
proper size tip liner, drive rolls, and any obstructions
or bends in the gun cable. Check for any other
factors that would impede the wire feeding. To
resume welding, simply pull the trigger. There is no
circuit breaker to reset, as the protection is done with
reliable solid state electronics.

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Power MIG® 215XT

E-6 E-6

NOTES

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-1 F-1

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11

Main Transformer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11

Wire Drive Motor and Tachometer Feedback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15

Output Bridge Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19

Contactor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21

Voltage Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23

Component Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27

Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27

Wire Drive Motor Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29

Output Diode Bridge Rectifier Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33

Output Capacitors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37

Main Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41

Fan Blade/Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47

Output Contactor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49

Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-52

WARNING

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

ELECTRIC SHOCK can kill.

• Never work on the inside of the machine without removing the
input power. You can receive a life threatening electrical shock if
you fail to do this . Only qualified technicians should perform
install a t io n , m a i nt e n an c e , and trou b l es h o ot i ng work on the
machine.

Power MIG® 215XT

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 listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos­sible symptoms that the machine may exhib­it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob­lems, wire feeding problems, and welding
problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” 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.

Step 3. RECOMMENDED
COURSE OF ACTION

The last column labeled “Recommended
Course of Action” 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 good or bad. If there are a
number of possible components, check the
components in the order listed
one possibility at a time until you locate the
cause of your problem.

All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

to eliminate

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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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Power MIG® 215XT

F-3 F-3

TROUBLESHOOTING AND REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK
can kill.

•

Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electricall y hot par ts.

CAUTION

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.

2. Check for loose connections at the PC board
to a ss ur e th a t the PC b oa rd is p ro pe rl y
connected.

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:

PC board can be damaged by static electricity.

- Rem o ve y o ur b o dy ’s s t at ic
charge before opening the static­shielding bag. Wear an anti-static
wris t strap. For sa f e t y, use a 1
Meg ohm resistive cord connected

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

to a g ro un de d p ar t of th e
equipment frame.

- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touc h in g t h e fram e to pr ev en t
stat i c bui l d- up . Be su r e not to
touch any electrically live parts at
the same time.

- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shield­ing bag.

- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.

- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop­er failure analysis.

4. Test the machine to determ ine if the failure

symp t om has b een c o rrect e d by t he
replacement PC board.

NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all
electrica l components can reach their operating
temperature.

5. Rem o ve t he r ep lacem e nt P C boar d a nd

subs t it ute it wi t h the ori g in al PC boa r d 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
fo r bad connect ions in the control wiring
harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC
boar d wa s the pr ob le m. Rei n st all the
replacement PC board and test the machine.

6. Alw a ys in d ic at e th a t thi s pro c edure wa s

foll o we d whe n warra n ty re p or ts are to b e
submitted.

NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.

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- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.

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Power MIG® 215XT

F-4 F-4

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Majo r p hy sical or e le ct ri cal damage is evident.

The mac h in e i s d e ad -- no o p en circuit voltage and no wi re feed when the gun trigger is activated. The cooling fan is not running.

There is no open circuit voltage or wire feed when the gun trigger is acti v at ed. The co o ling f a n i s running.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. C on ta ct y ou r loca l L in co ln
Electric authorized field service
facility.

1. M ake cer tain the input power
swit c h ( S 1) is in t h e “O N ”
position.

2. Check the input voltage at the
mach i ne . The in pu t vol t ag e
must match the rating plate and
the reconnect panel.

3. C h ec k f o r bl o wn or mi s si ng
fuses in the input lines.

1. Make sure the input voltage is
corr e ct and ma tc he s th e
nameplate rating and reconnect
panel configuration.

2. One of the two thermostats may
be o p en d ue to ma c hi ne
over h ea ting. If the m a ch in e
oper a te s nor m al ly a ft er a
cooling off period then check for
prop e r fan o pe ra ti on a n d
ve ntilation. Mak e certai n the
mach i ne ’s d ut y c yc le is no t
being exceeded.

RECOMMENDED

COURSE OF ACTION

1. Contact Lincoln Electric Service
Department 1-888-935-3877.

1. Check the input power switch
(S1). It may be faulty.

2. C h ec k for b r o ke n or mi s si ng
wires at the reconnect panel.

3. Perform the Main Transformer

Test.

1. The baff l e m o un te d re ct if ier
bridge ma y be faulty. C h e c k
and replace if necessary.

2. Perform the Main Transformer

Test.

3. C h ec k t he t he rm os ta ts and
as sociated leads for loose or
faul t y c o nn ec ti on s. S ee t he
Wiring Diagram.

4. T h e in te rn al trig g er in g
circuit/plugs may be faulty. See
the Wiring Diagram.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-5 F-5

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

(continued from previous page)

When the gun trigger is activated and the wire feeds normally, but there is no open circuit voltage.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

3. Check the gun trigger leads.
Leads #324 to #325 should have
continuity (zero ohms) when the
gun trigger is activated. If not,
the gun trigger or cable may be
faulty. Check or replace.

4. Check to make sure the switch
on the Magnum 100SG Adapter
Panel is in the Magnum Push
Gun Position.

5. If a spool gum option kit is
installed, check to make sure it is
set to the “normal” position if
using the Power MIG® 215XT
built in wire feeder.

1. Make sure the gun cable and
work cables are connected prop­erly and in good condition.

RECOMMENDED

COURSE OF ACTION

1. Check the output selector
switch for proper operation and
good connections.

2. Make sure the output selector
switch is in a good condition posi­tion and not between positions.

2. Perform the Output Contactor

Test.

3. Perform the Output Bridge
Rectifier Test.

4. Perform the Main Transformer
Test.

5. Check the heavy current carry­ing leads between the output
selector switch, output contac­tor, output bridge rectifier, and
the output terminals for loose or
faulty connections. See Wiring
Diagram.

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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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-6 F-6

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Output voltage and wire feed speed is present when the gun trigger is NOT activated.

The machines output is low. Welds
are “cold”. The weld beads are
rounded or “humped” demonstrat­ing poor wetting into the plate. The
machine cannot obtain full rated
output of 200 amps at 22VDC.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Remove the gun assembly. If the
problem is resolved, the gun
assembly is faulty. Repair or
replace. If the problem is NOT
resolved, the fault is within the
Power MIG® 215XT machine.

1. Check the input voltage. Make
sure the machine is configured
properly for the input voltage
being applied.

2. Make sure the settings for wire
feed speed and voltage are cor­rect for the process being used.

3. Make sure the electrode polarity
is correct for the process being
used.

4. Check the welding cables and
gun for loose or faulty connec­tions.

RECOMMENDED

COURSE OF ACTION

1. Check for “shorts” in the trigger
circuitry within the Power MIG®
215XT machine. See the
Wiring Diagram.

2. The control board may be faulty.

1. Check for loose or faulty con­nections on the heavy current
carrying leads inside the Power
MIG® 215XT. See the Wiring
Diagram.

2. The output capacitors may be
faulty. Check for loose connec­tions at the capacitors. Also
check for leaky capacitors.
Replace if necessary.

WARNING: The liquid electrolyte
in these capacitors is toxic.
Avoid contact with any portion of
your body.

The output voltage is continuous
when the gun trigger is NOT acti­vated. The wire feed functions nor­mally.

1. The output contactor may be
stuck closed.

CAUTION

3. The output selector switch may
be faulty. Check for good con­tact and continuity (zero ohms)
through the switch. See the
Wiring Diagram.

4. Perform the Output Contactor

Test.

5. Perform the Output Bridge
Rectifier Test.

6. Perform the Main Transformer
Test.

1. Perform the Output Contactor
Test.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-7 F-7

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

There is no gas flow when the gun trigger is activated . The wire feeds and the arc voltage is present.

The machine stops feeding wire
while welding. When the gun trig­ger is released and pulled again,
the wire feed starts.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. If a spool gun adapter is installed,
make certain the toggle switch in
the spool gun kit in the correct
position.

2. Check to make sure the switch on
the Magnum 100SG Adapter
Panel is in the Magnum Push
Gun Position.

3. Check the gas source and hoses
for kinks or leaks.

1. Check for a mechanical restriction
in the wire feed path. The gun
may be clogged.

2. Make sure the drive rolls and
guide plates are clean and are the
correct size.

3. Check the spindle for ease of rota­tion.

RECOMMENDED

COURSE OF ACTION

1. Check plug J1 on the control board
for loose or faulty connections. See
Wiring Diagram.

2. Check the gas solenoid by discon­necting it from leads #108A and
#116A&B. Apply a 12VDC external
supply to the solenoid. If the sole­noid does NOT activate then it may
be faulty. Replace.

1. Check the motor armature current.
Normal armature current is 2.0 to 2.7
amps maximum. If the motor arma­ture current is normal, and the motor
continues to shut-off, the control
board may be faulty. Replace.

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.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-8 F-8

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Rough wire feeding or the wire will
not feed but the drive rolls are turn­ing.

No control of wire feed speed.
Other machine functions are nor­mal.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WIRE FEEDING PROBLEMS

1. The gun cable may be kinked or
twisted.

2. Check the drive roll tension and
the position of the grooves.

3. Electrode may be rusted or dirty.

4. The contact tip may be damaged
or not the correct size.

5. Check the wire spindle for ease of
rotation.

6. Make certain the gun is pushed
all the way into the gun mount
and properly seated.

1. The wire feed speed control may
be dirty. Rotate several times and
check if the problem is resolved.

RECOMMENDED

COURSE OF ACTION

1. The wire speed control potentiome­ter may be faulty. Check or replace.
Normal potentiometer resistance is
10K ohms.

There is no wire feed when the gun
trigger is activated. Normal open
circuit weld voltage is present and
the gas solenoid functions normal­ly.

1. Check for adequate wire supply.

2. If the drive rolls are turning, check
for a mechanical restriction in the
wire feed path.

3. The gun liner may be clogged.
Check or replace.

4. If the drive rolls are not turning
when the gun trigger is activated,
contact your local Lincoln Electric
Authorized Field Service Facility.

CAUTION

2. Perform the Wire Drive Motor and
Tachometer Feedback Test.

3. The control board may be faulty.

1. Perform the Wire Drive Motor and

Tachometer Feedback Test.

2. The wire speed control potentiome­ter may be faulty. Check or replace.
Normal potentiometer resistance is
10K ohms.

3. The control board may be faulty.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-9 F-9

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Poor arc striking with electrode sticking or blasting off.

The arc is unstable and or “hunting” 1. Check for a worn or melted con-

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WELDING PROBLEMS

1. Make sure the settings for wire
feed speed and voltage are cor­rect for the process being used.

2. Make certain the gas shielding is
correct for the process being
used.

3. Make sure the machine’s recon­nect panel is configured properly
for the input voltage being
applied.

tact tip.

2. Check for loose or faulty connec­tions on the work and gun cables.

3. Make sure the electrode polarity is
correct for the welding process
being used.

4. Check for rusted or dirty electrode
wire.

5. Make sure the machine’s settings
and shielding gas are correct for
the process being used.

RECOMMENDED

COURSE OF ACTION

1. The output capacitors may be faulty.
Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.

WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid
contact with any portion of your
body.

2. Perform the Output Bridge
Rectifier Test.

1. Check for loose or faulty connections
at the output terminals, choke, out­put capacitors, output selector
switch, output contactor, and all
heavy current carrying leads. See
the Wiring Diagram.

2. Check the output selector switch for
proper operation and good connec­tions.

3. The output capacitors may be faulty.
Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.

WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid con­tact with any portion of your body.

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4. Perform the Output Bridge

Rectifier Test.

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-10 F-10

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The weld bead is narrow or ropy.
May have porosity with the elec­trode stubbing into the plate.

The contact tip seizes in the gas dif­fuser.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WELDING PROBLEMS

1. Make sure the welding proce­dures and electrode polarity are
correct for the process being
used.

2. Make certain the shielding gas is
correct and the flow is proper.

3. Make sure the weld joint is not
“contaminated”.

1. The tip is being over heated due
to excessive current and/or high
duty cycle.

2. A light application of high temper­ature anti-seize lubricant may be
applied to the contact tip threads.

RECOMMENDED

COURSE OF ACTION

1. Perform the Output Bridge
Rectifier Test.

2. The output capacitors may be faulty.
Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.

WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid
contact with any portion of your
body.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-11 F-11

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical 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

3/8" wrench
5/16” Nutdriver
Volt-ohmmeter

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Power MIG® 215XT

X8

X7

X6

X5X4

X3

X2

F-12 F-12

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER TEST (continued)

FIGURE F.1 – OUTPUT SELECTOR SWITCH TERMINALS

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PROCEDURE

WARNING

THE ON/OFF POWER SWITCH will be “hot”
during these tests.

NOTE: Secondary voltages will vary

proportionately with the primary input
voltage.

1. Disconnect the main input power supply to the
machine.

2. Remove the case top and side panels with a 3/8”
nutdriver.

3. Remove the tool tray with a 5/16” nut driver.

4. Locate leads X2 thru X8 located on the output
selector switch. See Figure F.1.

5. Locate lead X1 located on the output rectifier
assembly. See Figure F.2.

6. Locate leads X9 and X10. See Figure F.3.

7. Connect main input power to the machine.

8. Turn the Power MIG® 215XT ON/OFF Power
Switch to the ON position.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts
such as output terminals or inter­nal wiring.

• All input power must be electrical­ly disconnected before proceed­ing.

9. Carefully make the following voltage tests. See
Table 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.

Power MIG® 215XT

X1

X9

X10

F-13 F-13

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER TEST (continued)

FIGURE F.2 – LEAD X1

FIGURE F.3 – LEAD X9 & X10

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Power MIG® 215XT

F-14 F-14

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER TEST (continued)

TABLE F.1 – TEST POINTS

INPUT VOLTAGE TEST POINTS

230 VAC

230 VAC

230 VAC

230 VAC

230 VAC

230 VAC

230 VAC

230 VAC

12. If ALL the voltages tested are incorrect or miss­ing, test for correct nameplate input voltage
between the H1 lead at the ON/OFF POWER
SWITCH to H2 or H3 at the reconnect panel.
Voltage tested will vary depending on input
voltage connection. See Wiring Diagram for
test point locations.

A. If the input voltage test is incorrect, check for

loose or broken leads between the reconnect
panel and the ON/OFF POWER SWITCH.

EXPECTED VOLTAGE READING

X1-X2

X1-X3

X1-X4

X1-X5

X1-X6

X1-X7

X1-X8

X9-X10

13. If the correct nameplate voltage is being
applied to the main transformer and one or
more of the secondary voltages are missing or
are incorrect, the main transformer may be
faulty. Replace.

14. When test is complete, replace tool tray, case
sides and top.

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

B. Test the ON/OFF POWER SWITCH for proper

operation.

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Power MIG® 215XT

F-15 F-15

TROUBLESHOOTING AND REPAIR

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical 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

5/16” Nutdriver
Volt-Ohmmeter

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Power MIG® 215XT

Black
Tach

J11J11

Black
Arm

White
Arm

Blue
Tach

Red
Tach

F-16 F-16

TROUBLESHOOTING AND REPAIR

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)

FIGURE F.4 – PLUG J4

PROCEDURE

NOTE: POLARITY MUST BE OBSERVED FOR

THESE TESTS.

Test for correct wire drive motor armature voltage.

1. Disconnect main input power to the machine.

2. Open the side panels and remove the tool tray
using a 5/16” nutdriver.

3. Locate plug J4 on the wiring harness. See
Wiring Diagram.

4. Locate the black and white armature leads on
plug J4. See Figure F.4.

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Power MIG® 215XT

F-17 F-17

TROUBLESHOOTING AND REPAIR

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)

5. Make the following voltage tests:

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts
such as output terminals or internal
wiring.

• All input power must be electrically
disconnected before proceeding.

a. Turn the machine OFF between each test.

b. Carefully insert the meter probes into the lead

side of plug J4. See Figure F.4.

c. Turn the machine ON and pull the gun trigger

to conduct the voltage test.

FROM LEAD

Black
Armature
Lead

FROM LEAD

White
Armature
Lead

FROM LEAD

2-29 VDC

(varies depending
on wire feed
speed)

TEST FOR SUPPLY VOLTAGE TO TACHOME­TER

1. Disconnect the main AC input power to the
machine.

2. Locate plug J4.

3. Locate the tach leads on plug J4. See Figure

F.5.

4. Connect the main input power to the machine.

5. Make the following voltage tests:

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts
such as output terminals or internal
wiring.

• All input power must be electrically
disconnected before proceeding.

a. Turn the machine OFF between each test.

6. If the voltage to the wire drive motor armature is
zero, check the wires between plug J4 and the
wire drive motor. Also check the electrical con­nector J5 for proper connections and jumper
plug. See the Wiring Diagram.

7. 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.

8. If the motor is running at high speed and the
armature voltage is high and uncontrollable,
Proceed with the tachometer test.

b. Carefully insert the meter probes into the

lead side of plug J4.

FROM LEAD

Black (-)

FROM LEAD

Red (+) 5-6 VDC

FROM LEAD

6. If the 5-6 VDC is present, check the leads to the
tachometer circuit.

7. If the leads are okay and 5-6 VDC is present, the
correct voltage is being received from the con­trol PC board. Continue with the supply voltage
to tachometer test.

8. If the 5-6 VDC is not present and the leads are
okay, the control PC board may be faulty,
replace the control PC board. Also check plug
J5 and the jumper plug. See Wiring Diagram.

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Power MIG® 215XT

F-18 F-18

Black
Tach

J11J11

Black
Arm

White
Arm

Blue
Tach

Red
Tach

TROUBLESHOOTING AND REPAIR

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)

FIGURE F.5 – PLUG J4

TEST FOR FEEDBACK VOLTAGE TO
CONTROL BOARD

1. Disconnect the main AC input power to the
machine.

2. Locate plug J4 and the tach leads. See
Figure F.5.

3. Connect main input power to the machine.

4. Make the following voltage tests:

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such
as output terminals or internal wiring.

• All input power must be electrically dis­connected before proceeding.

a. Turn the machine OFF between each

test.

FROM LEAD

Black (-)

5. If the 3.0 to 4.0 VDC is present, the tachometer
circuit is sending the correct feedback signal
to the control PC board. Check the leads
and plug J5. See the Wiring Diagram.

6. If the 3.0 to 4.0 VDC is NOT present or NOT
correct, the control PC board is not receiving
the proper feedback voltage from the
tachometer circuit.

7. If the leads are okay, the tachometer circuit
may be faulty, replace the tachometer circuit.

TO LEAD

BLUE (+)

EXPECTED

VOLTAGE

3.0 TO 4.0
VDC

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b. Carefully insert the meter probes into

the lead side of plug J4. See Figure
F.5.

c. Turn the machine ON and pull the gun

trigger to conduct the voltage test.

Power MIG® 215XT

8. Replace the tool tray.

F-19 F-19

TROUBLESHOOTING AND REPAIR

OUTPUT BRIDGE RECTIFIER TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will determine if a diode is “shorted” or “leaky”. See the machine waveform
section in this manual for normal and abnormal output wave forms.

MATERIALS NEEDED

Analog Volt-ohmmeter or Diode Tester
3/8” Nutdriver
1/2” Nutdriver

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Power MIG® 215XT

Front

-

+

Negative Lead

F-20 F-20

TROUBLESHOOTING AND REPAIR

OUTPUT BRIDGE RECTIFIER TEST (continued)

FIGURE F.6 – RECTIFIER TEST POINTS

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PROCEDURE

1. Remove input power to the Power MIG® 215XT
machine.

2. Using the 3/8” nutdriver, remove the left case
side.

3. Locate and disconnect the negative lead from
the output rectifier bridge assembly. Be sure
there is no electrical contact between the recti­fier and the lead. See Figure F.6.

NOTE: Do not disassemble the rectifier assembly.

Power MIG® 215XT

4. Test for “shorted” or “leaky” diodes by checking
from the anodes to the cathodes of the diode
heatsink plates. The readings should be high
resistance in one polarity and low resistance in
the opposite polarity.

5. If any of the diodes are “leaky” or “shorted” the
output rectifier assembly should be replaced.

6. When the test is complete, replace the negative
output lead previously removed.

7. Replace the left case side.

F-21 F-21

TROUBLESHOOTING AND REPAIR

CONTACTOR TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical 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
7/16” Wrench

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

107A

106C

106B

Output
Contactor

F-22 F-22

TROUBLESHOOTING AND REPAIR

CONTACTOR TEST (continued)

FIGURE F.7 – CONTACTOR TERMINALS AND LEADS

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PROCEDURE

1. Remove the input power to the Power MIG®
215XT machine.

2. Using the 5/16” Nutdriver, remove the tool tray.

3. Locate and remove leads 106B, 106C and 107A
from the contactor coil terminals. See Figure
F.7. See the Wiring Diagram.

4. Using the 7/16” wrench, remove one lead from
the contactors large terminals. See Figure F.7.
See the Wiring Diagram.

5. Carefully apply 12 VDC to the contactor coil
leads. (small terminals)

CAUTION

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.

6. If the contactor does not activate when the
12VDC is applied, the contactor is faulty.
Replace.

Power MIG® 215XT

7. If the contactor activates when the 12VDC is
applied, check the resistance between the two
large terminals with the contactor activated. The
resistance should be very low (0 to 1 ohm).

8. If the resistance is “high” or “open” between the
two large terminals when the contactor is acti­vated, the contactor is faulty. Replace.

9. If the contactor activates and the resistance
between the terminals is low when the 12 VDC
is applied, the contactor is good

NOTE: When the contactor is not activated, the

resistance between the terminals should
be very high (infinite). If the resistance is
always low, the contacts are “stuck” and
the contactor is faulty. Replace.

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.

12. Replace the tool tray.

F-23 F-23

TROUBLESHOOTING AND REPAIR

TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

(MAX TAP “G”)

0 volts

10.0V

5ms

MACHINE LOADED TO 200 AMPS AT 22 VDC

This is a typical DC output voltage
waveform generated from a properly
operating machine. Note that each
vertical division represents 10 volts
and that each horizontal division rep­resents 5 milliseconds in time. The
machine was loaded with a resistance
grid bank.

Note: Scope probes connected at

machine output terminals: (+)
probe to electrode, (-) probe to
work.

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SCOPE SETTINGS

Volts/Div.....................10V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

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Power MIG® 215XT

F-24 F-24

TROUBLESHOOTING AND REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”)

0 volts

20.0V

1.0 ms

This is a typical DC output voltage
waveform generated from a properly
operating machine. Note that each
vertical division represents 20 volts
and that each horizontal division rep­resents 1.0 milliseconds in time.

Note: Scope probes connected at

machine output terminals: (+)
probe to electrode, (-) probe to
work.

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SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep ..1.0 ms/Div.

Coupling.............................DC

Trigger.........................Internal

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Power MIG® 215XT

F-25 F-25

TROUBLESHOOTING AND REPAIR

ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

(MAX TAP “G”)

ONE OUTPUT DIODE NOT FUNCTIONING

0 volts

20.0 V

5ms

MACHINE LOADED TO 180 AMPS AT 16 VDC

This is NOT a typical DC output volt­age waveform. One output diode is
not functioning. Note the increased
ripple content. One diode was discon­nected to simulate an open or non­functioning output diode. Each vertical
division represents 20 volts and each
horizontal division represents 5 mil­liseconds in time. The machine was
loaded with a resistance grid bank.

Note: Scope probes connected at

machine output terminals: (+)
probe to electrode, (-) probe to
work.

SCOPE SETTINGS

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Volts/Div.....................20V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

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Power MIG® 215XT

F-26 F-26

TROUBLESHOOTING AND REPAIR

ABNORMAL OPEN CIRCUIT VOLTAGE

OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”)

0 volts

20.0 V

This is NOT a typical DC output volt­age waveform. The output capacitors
are not functioning. Note the lack of
“filtering” in the output waveform. The
output capacitor bank was disconnect­ed. Each vertical division represents
20 volts and each horizontal division
represents 5 milliseconds in time.

Note: Scope probes connected at

machine output terminals: (+)
probe to electrode, (-) probe to
work.

5ms

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep .....5 ms/Div.

Coupling.............................DC

Trigger.........................Internal

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-27 F-27

TROUBLESHOOTING AND REPAIR

CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Control Board for
replacement.

MATERIALS NEEDED

5/16” Nutdriver

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Power MIG® 215XT

DEPRESS
LOCKING TAB ON
MOUNTING PIN

F-28 F-28

TROUBLESHOOTING AND REPAIR

CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE

(continued)

FIGURE F.8 – CONTROL BOARD MOUNTING PINS

PROCEDURE

1. Remove power to the machine.

2. Using a 5/16” nutdriver, remove the three
screws securing the tool tray.

3. Locate the control board.

4. Disconnect all associated plugs and leads con­nected to the control board.

5. Depress the retaining pins on the sides of the
four nylon mounts to release the control board.
See Figure F.8.

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6. Carefully remove the control board.

7. Mount the new board to the nylon mounting
pins.

8. Reconnect any plugs or leads previously
removed.

9. Replace the tool tray previously removed.

Power MIG® 215XT

F-29 F-29

TROUBLESHOOTING AND REPAIR

WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Wire Drive and
Tachometer for repair or replacement.

MATERIALS NEEDED

5/16” Nutdriver
9/16” Nutdriver
Pliers
Small Flathead Screwdriver

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Power MIG® 215XT

Wire Drive

F-30 F-30

TROUBLESHOOTING AND REPAIR

WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE

(continued)

FIGURE F.9 – WIRE DRIVE LOCATION

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PROCEDURE

1. Remove power to the machine.

2. Lift cover to gain access to the wire drive. See
Figure F.9.

3. Using a pair of pliers, disconnect the gas hose
from the bottom of the wire drive. See Figure

F.10.

4. Using a 9/16” nut driver, remove the thick black
positive lead located just above the gas hose.

See Figure F.10.

NOTE: Disconnect lead from the wire drive motor

assembly, not the machine.

Power MIG® 215XT

5. Using a 5/16” nutdriver, remove the three
mounting screws next to the wire drive assem­bly. See Figure F.10.

6. Using a 5/16” nutdriver, remove the two screws
on the case front assembly. See Figure F.11.

7. Carefully maneuver the wire drive assembly out
the side of the machine to gain access to plug
J4. See Wiring Diagram.

8. Disconnect plug J4.

Gas Hose

9/16" Bolt

5/16" Sheet
Metal Screws

5/16"
Monuting
Screws

F-31 F-31

WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE

TROUBLESHOOTING AND REPAIR

(continued)

FIGURE F.10 – WIRE DRIVE HOSE & LEAD LOCATION

FIGURE F.11 – MOUNTING SCREW LOCATIONS

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Power MIG® 215XT

F-32 F-32

TROUBLESHOOTING AND REPAIR

WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE

(continued)

1. Place the new wire drive assembly into its prop­er position.

2. Connect plug J4.

3. Maneuver assembly back into its original posi­tion.

4. Replace all mounting screws previously
removed.

5. Using a 3/4” nut driver, replace the thick black
lead previously removed.

6. Reconnect the gas hose to the wire drive
assembly.

7. Close case wrap around cover.

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Power MIG® 215XT

F-33 F-33

TROUBLESHOOTING AND REPAIR

OUTPUT DIODE BRIDGE RECTIFIER

REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Output Diode Bridge
Rectifier for repair or replacement.

MATERIALS NEEDED

3/8” Nutdriver
1/2” Nutdriver
5/16” Nutdriver

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

OUTPUT DIODE
BRIDGE
RECTIFIER

F-34 F-34

TROUBLESHOOTING AND REPAIR

OUTPUT DIODE BRIDGE RECTIFIER

REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.12 – OUTPUT DIODE BRIDGE RECTIFIER LOCATION

PROCEDURE

1. Using a 3/8” nutdriver, remove the left side of
the case wraparound cover.

2. Locate the output diode bridge rectifier. See

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Figure F.12.

3. Using a 1/2” nutdriver label and remove the four
thick black leads connected to the rectifier.

NOTE: Be sure to label lead terminals also.

4. Label and remove leads 104A and 104B. See
Wiring Diagram.

5. Using a 5/16” nutdriver locate and remove the
four bolts mounting the rectifier bracket to the
bottom of the machine. These bolts can be
accessed easily from the bottom of the
machine. See Figure F.13.

6. Carefully manipulate the output diode bridge
rectifier and the mounting bracket out of the left
side of the machine.

Take note of washer placement upon
removal.

Power MIG® 215XT

7. Using a 1/2” nutdriver remove the three bolts
mounting the bracket to the rectifier. The recti­fier is now ready for repair or replacement. See

Figure F.13.

8. Mount the new rectifier to the mounting bracket
using the three 1/2” bolts.

9. Carefully manipulate the rectifier and mounting
bracket as a one back into the machine to its
proper location.

10. Mount the unit to the bottom of the machine

using the four 5/16” mounting bolts previously
removed.

11. Reconnect leads 104A and 104B previously

removed.

12. Reconnect the four thick black leads previous-

ly labeled and removed using a 1/2” nutdriver.

13. Replace the left side of the case wraparound

cover.

5/16" Mounting
Bracket Mounting
Bolts

1/2" Rectifier
Mounting Bolts

Mounting
Bracket

F-35 F-35

REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.13 – OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET

TROUBLESHOOTING AND REPAIR

OUTPUT DIODE BRIDGE RECTIFIER

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Power MIG® 215XT

F-36 F-36

NOTES

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Power MIG® 215XT

F-37 F-37

TROUBLESHOOTING AND REPAIR

OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Output Capacitors for
repair or replacement.

MATERIALS NEEDED

3/8” Nutdriver
1/2” Wrench

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Power MIG® 215XT

LOWER RIGHT
CASE WRAPAROUND
COVER

CAPACITOR BANK

ASSEMBLY

F-38 F-38

TROUBLESHOOTING AND REPAIR

OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE

(continued)

FIGURE F.14 – CAPACITOR BANK LOCATION

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PROCEDURE

1. Using a 3/8” nutdriver, remove the lower right
side case wraparound cover. See Figure F.14.

2. Locate capacitor bank. See Figure F.14.

3. Label and remove the five leads connected to
the capacitor bank using a 1/2” wrench. Note
washer position upon removal. See Figure

F.15.

4. Using a 3/8” nutdriver, remove the three capac­itor bank nuts and lock washers from the three
mounting bolts. See Figure F.15.

Power MIG® 215XT

5. Remove the capacitor bank assembly from the
machine.

6. Place the new capacitor bank into its proper
location inside the machine.

7. Replace the three 3/8” nuts and lock washers
previously removed.

8. Using a 1/2” wrench, reconnect the five labeled
leads and associated washers previously
removed.

9. Replace the lower right side case wraparound
cover previously removed.

}

{

3/8" Nuts &
Lock washers
(3 places)

Lead Mounting
Bolts

F-39 F-39

OUTPUT CAPACITORS REMOVAL AND REPLACEMENT PROCEDURE

TROUBLESHOOTING AND REPAIR

(continued)

FIGURE F.15 – MOUNTING SCREW / BOLT LOCATIONS

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Power MIG® 215XT

F-40 F-40

NOTES

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

F-41 F-41

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Main Transformer for
repair or replacement.

MATERIALS NEEDED

3/8” Nutdriver
7/16” Nutdriver
1/2” Nutdriver
5/16” Nutdriver
Flathead Screwdriver

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

Main Transformer

1/2" Mounting
Bolts

F-42 F-42

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE

(continued)

FIGURE F.16 – MAIN TRANSFORMER LOCATION

PROCEDURE

1. Using a 3/8” nutdriver, remove both sides of the
case wraparound cover.

2. Using a 5/16” nutdriver, remove the tool tray.

3. Locate the main transformer. See Figure F.16.

4. Label and disconnect leads X9, X10, 104B, &
104C. See Figure F.17.

5. Using a flathead screwdriver, Label and discon­nect lead H1B and other associated lead con­nected to the same terminal. These leads are
connected to the ON/OFF switch. See Figure

F.17.

6. Using a 7/16” nutdriver, Label and disconnect
leads X8, X7, X6, X5, X4, X3, & X2 from the
switch assembly. Note washer position upon
removal. See Figure F.18.

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Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

7. Using a 1/2” nutdriver, label and remove lead
X1 from the output diode bridge rectifier.

8. Using a 5/16” Nutdriver, open the rear access
panel. See Figure F.20.

9. Disconnect lead 118 from the rear access
panel. See Figure F.21.

10. Feed lead 118 toward the inside of the

machine.

11. Cut any necessary cable ties.

12. Remove any necessary wiring harnesses.

13. Disconnect lead 121. See Figure F.19.

14. Using a 1/2” nutdriver, remove the four main

transformer mounting bolts and associated
washers. See Figure F.16.

Power MIG® 215XT

X10

X9

104B

104C

H1B

F-43 F-43

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE

(continued)

FIGURE F.17 – LEADS X9, X10, 104B, 104C, & H1B

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15. Carefully maneuver the main transformer out
the left side of the machine.

NOTE: Two people may be needed to maneuver

the main transformer out of the machine.

REPLACEMENT

1. Carefully maneuver the new main transformer

back into the machine and onto its mounting
studs.

2. Using a 1/2” nutdriver, mount the main trans-

former in its proper position.

3. Reconnect leads 118 and 121 previously

removed.

4. Using a 5/16” nutdriver, close the rear access

panel previously opened.

Power MIG® 215XT

5. Reconnect lead X1 to the output diode bridge
rectifier.

6. Reconnect leads X8, X7, X6, X5, X4, X3, & X2
previously removed from the switch assembly.

7. Reconnect lead H1B and the other associated
lead connected to the same terminal. These
leads are connected to the ON/OFF switch.

8. Replace any necessary cable ties and wiring
harnesses.

9. Reconnect leads X9, X10, 104B, & 104C. See
Wiring Diagram.

10. Using a 5/16” nutdriver, replace the tool tray.

11. Using a 3/8” nutdriver, replace both sides of the

case wraparound cover.

X8

X7

X6

X5X4

X3

X2

Front

-

+

121

118

F-44 F-44

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE

(continued)

FIGURE F.18 – LEADS SWITCH LEADS

FIGURE F.19 – LEAD 121 & 118

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

5/16" Nut

REAR
ACCESS
PANEL

230V

208V

4

L1

L2

Lead 118

F-45 F-45

TROUBLESHOOTING AND REPAIR

MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE

(continued)

FIGURE F.20 – REAR ACCESS PANEL

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FIGURE F.21 – REAR ACCESS PANEL (CLOSE-UP)

Power MIG® 215XT

F-46 F-46

NOTES

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Power MIG® 215XT

F-47 F-47

TROUBLESHOOTING AND REPAIR

FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Fan Blade and Fan Motor
for repair or replacement.

MATERIALS NEEDED

3/8” Nutdriver
5/16” Nutdriver
11/32” Open-End Wrench
Flathead Screwdriver

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

REAR

5/16" Bolts

}

}

Fan
Mounting
Band

11/32"
Mounting
Nuts

Fan
Blade

Fan
Motor

F-48 F-48

TROUBLESHOOTING AND REPAIR

FAN BLADE / MOTOR REMOVAL AND REPLACEMENT PROCEDURE

(continued)

FIGURE F.22 – FAN MOUNTING BOLTS

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

PROCEDURE

1. Using a 3/8” nutdriver, remove the lower right
side of the case wraparound cover.

2. Perform the Output Capacitors Removal and

Replacement Procedure.

3. Using a 5/16” nutdriver, remove the four fan
mounting screws from the rear of the machine.
See Figure F.22.

4. Using an open end 11/32” wrench, remove the
two fan motor mounting nuts and lockwashers.
See Figure F.22.

5. Using a flathead screwdriver, loosen the fan
blade mounting band. See Figure F.22.

6. Pry the fan blade off of the mounting shaft.

NOTE: If fan blade cracks or breaks upon

removal, replace it.

7. Carefully maneuver the fan motor and fan blade
out of the right side of the machine.

Power MIG® 215XT

8. Replace the fan motor and fan blade if neces­sary.

9. Tighten the fan blade mounting band.

10. Carefully maneuver the fan assembly into its

original position.

11. Replace the two 11/32” fan motor mounting

nuts and lockwashers.

12. Replace the four 5/16” fan assembly mounting

screws in the rear of the machine.

NOTE: Make sure the fan blade is free to rotate

when all of the mounting bolts are
replaced.

13. Perform the Output Capacitors Removal and

Replacement Procedure.

14. Replace the lower right case cover.

F-49 F-49

TROUBLESHOOTING AND REPAIR

OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Output Contactor for
repair or replacement.

MATERIALS NEEDED

7/16” Wrench
5/16” Nutdriver

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

107A

106C

106B

Output
Contactor

F-50 F-50

TROUBLESHOOTING AND REPAIR

OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE

(continued)

FIGURE F.23 – OUTPUT CONTACTOR LEADS

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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

PROCEDURE

1. Using a 5/16” nutdriver, remove the three
screws securing the tool tray.

2. Locate the output contactor. See Figure F.23.

3. Using a 7/16” wrench, label and remove the two
thick black leads at the top of the output con­tactor. Note lead and washer placement for
reassembly.

4. Remove lead 107A and note lead placement.
See Figure F.23.

5. Remove leads 106B and 106C. See Figure
F.23.

6. Using a 7/16” wrench, remove the three mount­ing bolts from the output contactor. Note wash­er positions for replacement. See Figure F.24.

Power MIG® 215XT

7. Replace output contactor.

8. Using a 7/16” wrench, mount the new output
contactor in its proper location.

9. Reconnect leads 106B, 106C, & 107A to their
proper terminals. See Wiring Diagram.

10. Reconnect the two thick black leads previously

removed from the top of the output contactor.

11. Replace the tool tray using a 5/16” nutdriver.

7/16" Mounting
Bolts

F-51 F-51

OUTPUT CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE

TROUBLESHOOTING AND REPAIR

(continued)

FIGURE F.24 – OUTPUT CONTACTOR MOUNTING BOLTS

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

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

OPEN CIRCUIT VOLTAGE

35 - 40 VDC

WIRE SPEED RANGE

50 - 700 IPM (1.27 - 17.8 m/minute)

Maximum Idle Watts

150

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

G-1 G-1

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram (L12184-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2

Schematic – Complete Machine (L12308-1 PG1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3

Schematic - Complete Machine with Spool Gun (L12308-1 PG2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4

Schematic – Control PC Board * – (G4414-2 PG1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5

Schematic – Control PC Board – (G4414-2 PG2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6

Schematic – Control PC Board – (G4414-2 PG3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7

TABLE OF CONTENTS - DIAGRAM SECTION

* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-lay-

ered and are therefore considered to be unserviceable. Assembly drawings of these boards are
no longer provided.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Power MIG® 215XT

POWER MIG 215XT (208/220/230V) FOR COD

E 1

1521

J1

C

AVIT

YNUMBERING

SE

QUENCE

(COMPONENT S

IDE

OF P

.C. BOARD)

J2

NOTES:

N.A.

WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF
IMMEDIATE AND FUTURE APPLICATIONS.

N.B.

THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIVE”. TO CHANGE POLARITY, TURN
THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK
STUD.

1

7

2

3

4

5

6

8

1

J1

10

11

12

9

110

3A

111

3A

110

9A

1108A

1116A

1116B

110

9A

110

8A

110

7A

110

6A

110

5A

110

4A

110

3A

110

2A

110

4B

110

1A

X9

TRANSF

ORM

ER

TH

ERM

OSTAT

RECT

IFI

ER

ASSEMBLY

TH

ERM

OSTAT

G

F

E

D

C

B

A

X10

X9

CONTACT

OR

FAN

MOTOR

X5

X7

X8

27.8V

X6

SINGLE PHASE

BRIDGE

RECTIFIER

2

1

4

3

2

TRIGG

ER

GUN

CONTR

OL BOAR

D

P.

M.

R2

X1

TRANSF

ORM

ER

POWER

H2

X3

W

CHOK

E

OUTPUT

B

X2

H1

220

H1

H4

50

W

40

OH

MS

50V

31,000

MFD

C1

AND C

2

+

+

C2

SU

PPLY L

INE

TOS

INGLEPH

ASE

L1 L2

6

3

L1

4
5

J2

X4

C1

H2

G

PANEL

RECONNECT

S1

SWITCH

L

INE

H1

208V

L2

B

SPE

ED

WIRE

FE

ED

H3

GEARB

OX

MOTOR/

W

ORK

TO

R

1

H3 H4

324

325

W

CODE

NATION

AL ELECTRIC

AL

T

O

GROUND P

ER

USED FOR ADDITIONAL

SPOOL GUN OPTIONS

J3

1

2

J3

1

4

3

2

J5

**

111

0A

111

1A

1

4

3

2

PA

GAS

SOLENOID

1107A

1106

C

1106C

1116B

1105A

1105B

111

3A

1

4

3

2

1

4

3

2

6

5

T
A
C
H

1115A

D

B

U

R

B

U

J4

**

9

PA

J4 (TRIG

GER,

T

ACHOMET

ER,

MOTOR S

IDE)

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE

B-BLACK
W -

WHITE

R -

RED

U -

BLUE

INDICATES CONNECTOR CAVITY No.

**

CAVITY

NUMBERING SEQUENCE

(NON-LEAD SIDE OF CONNECTOR)

8

16

1

4

6

1

3

8

1

4

5

1

2

8

7

6

5

6

5

13

14

15

16

110

4C

1104C

1104D

110

4D

1111A

111

2A

1101A

1102A

111

4A

111

5A

4

6

1

3

110

4A

111

6A

-

+

TAP SELECT

OR

SWITCH

230

V

B

X11

115V

X12

D

15A

X11

X12

401A

402A

403

115V

401

402

1

4

3

2

J6

1110A

1114A

1106A

W

B

1105B

1112A

R.

F. FILTER

327

326

1117

1118

1118A

1123

1124

1117A

1123

1124

1122

1121

1121

1122

S

WITCH

AND GUN TRIG

GER

SHOWN IN MAGNUM10

0 L

PUSH

GUN MODE.

SWITCH

TORROID

10

0SG REA

DY

G-2

WiriNG DiaGram - cOmplETE machiNE - l12184-1

ElEcTrical DiaGramS

G-2

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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 miG® 215XT

J1

,

J1

4

CAVITY

NUM

BERING SEQUEN

CE

(

COMPONENT S

IDE OF P.C. BOARD

)

J2

J3

9

PA

J4 (TRIGGER,

T

ACH

OMETER,

MOT

ORSIDE)

8

16

1

4

6

1

3

8

1

4

5

1

2

4

6

1

3

(NON

-LEAD SIDE OF CON

NECTOR

)

LEAD

COLORCO

DE:

B-BL

ACK

G-GRE

EN
O-ORANGE
R-RE

D

U-BLU

E

W-WHIT

E

Y-Y

ELLO

W

COMPONENTVALUE U

NIT

S:

CAPA

CITOR: MFD/VOLTS

RESI

STO

R: OHMS/W

ATTS

CO

NNE

CTORPIN NUMBERS:

VIEW OFCONNECTOR ON PC BOARD

1

2

6

712

LATC

H

EX.12PIN CONNECTOR

LABELS:

COMM

ON

FRAME GROUND

EA

RTH

GROU

ND

L12308-1

POWER MIG

216

MACHINESCHEM

ATI

C

NO

NE

L12308

DO N

OT SCALE

THISD

RAW

ING

EQUIPMENTTYPE

:

SUBJEC

T:

UF

CRM41

566

1

PAGE___

OF

___

2

ENGINE

ERING CONTROLLED

MANUFACTURER:

No

T

HIS

DOC

UMENT CONTAINS PROP

RIETA

RY INFORMATIONOWNED BY LINC

OLN

GLOBAL, IN

C. AND MAY NOT BE DUPLICATED,C

OMMUNICATED

TO OTHER PARTIES ORUSEDFO

R A

NY PURP

OSE WIT

HOU

T THE EXPRESSWRITTE

N PE

RMISSIONOF LINCOLN

GLOBAL, IN

C.

PROPRIETARY &
CONFIDENTIAL:

REVISEDPAGE

2.

t

MAT

ERIAL TOLERANCE ("")

TO AGREE

WITH PUBLISHED

STANDARDS.

O

N ALL AN

GLES IS± .5

OF A

DEG

REE

ON 3 PLACEDECIM

ALSIS ±.002in.

(± 0.05

mm)

O

N 2

PLACE DEC

IMALS IS± .02 in. (± 0.5

mm)

U

NLESS

OTHERW

ISE

SPECIFIED

TOLERANCE

:

MANUFACTURING TOLERANCE PER

E2056

CHAN

GE DETAIL:

REFEREN

CE:

SCA

LE:

MATE

RIAL

DISPO

SITION:

APP

ROV

AL

DAT

E:

PROJECT
NU

MBE

R:

DOCUMENT
N

UMBER:

DOCUMENT
REVISION:

U

NITS:

IF

PRIN

TED

@A2 S

IZE

IN

CH

4/9/

2010

cstuble

T. S

PEAR

OBS

DRAWN

BY:

E

NGINEE

R:

CLEVELAND

APPROVE

D:

CONTROL:

C

L12308-1

1

1104B

G

F

E

D

C

B

A

X10

X9

CONTACTOR

(NOR

MALLY

OPEN)

FAN

MO

TOR

X5

X7

X8

27.8V

X6

SINGLE

PHASE

B

RIDGE

RE

CTIFIE

R

4

3

2

T

RIGGER

G

UN

R2

10K

POT

X1

TRANSFO

RME

R

MAIN

H2

X3

X2

H1

22

0

H1

H4

SUPPLY LINE

TO SINGLE PHASE

L1 L2

L1

X4

H2

G

PANEL

RECO

NNE

CT

S1

SWI

TCH

LINE

H1

20

8V

L2

B

H3

WO

RK

TO

H3 H4

324

325

W

CODE

NATIONAL

ELECTR

ICAL

TO

GROUN

D PER

1107

A

1104A

TAP

SELEC

TOR SWITCH

23

0

V

X11
115V

X12

CIR

CUIT

BREAKER

15A

X12

403

115V

401A

2J6

R.

F. FILTE

R

12J1

8J1

1112A

1108A

CONTROL

P.C. BOARD

(SCHEMATICG441

4)

16J1

1116A

MOTO

R -

COM

SOLEN

OIDOPE

N = 3

6.5

VDC

5J1

1105A

MOTO

R +

1J1
2J1

1101A
1102A

15J1

1115A

5VDCTACH

SUPPLY

T

ACHSIGN

AL

T

ACH C

OM

3J4
4J4
5J4

R
U
B

R
U
B

TACHMOTOR / GEARBOX

OHMS = 1. 5 TO 6 .5

1.8 VDC@ 50 IN/MIN

26.5 VDC @ 700 I N/MIN

LOCA TED
ON R IGH T
CASE BA CK

8J4
7J4

BW

OUTPUT

CHOKE

5

0

w

a

t

t

s

4

0

o

h

m

s

R1

+

31000/50

LOCA TEDON BASE I N
THE MI DDLE OF THE
MACHI NE

CONTROL S T HE
FUNCTIONALITY OF
THE MACHINE

-

+

RECTIFIER
DIODE
BRIDGE

LOCATED ON

TRANSFO RMER

BAFFLE

LOCA TEDON FRO NT
OF MACHI NE' SBASE

11

06A

11

06B

X91114A

X10

12.0

VAC

14.1

VAC

16.4

VAC

18.7

VAC

20.9

VAC

23.2

VAC

25.6

VAC

LOCA TED ON
MACHI NE' S BAS E
P.C. BOARD
COMPARTMENT SI DE

LOCATEDI NSIDE
OF P.C. BOARD
COMPARTMENT

0VNOTRIGGER

8.6V TRIG

GER

LOCA TEDON
CASE BA CK

401
402

402A

TAPG

= 3

6.0

VDC

TAPF

=

32.8

VDC

TAPE

= 2

9.6

VDC

T

AP D

=

26.5

VDC

T

AP C

=

23.2

VDC

TAPB

= 2

0.0

VDC

TAPA

= 1

6.9

VDC

LOCA TED ON MACHI NE' S
BASE, TOWARDS BACK,
WI RE D RI V E SI D E

BANK OF TWO
CAPACIT ORS

14J1

1114A

COM

6J1

1106A

+3

9.2

5VDC

7J1

1107A

CONTACTOR

B

W

TOROID
(1

TURN)

TOROID
(1

TURN)

4J6

11J1

1111A

4J1

LOCA TED ON
MAI N
TRANS FORM ER
WI NDI NGS

LOCA TEDON
INPUT
RECTI FI ER

12V
20 OHM COIL
6VHOLD

GAS SOLENOID

13J1

1113A

3J1

1103A

9J1

1109A

LOCATED ON
CASE FRONT

ADJUSTS WIRE
FEEDSPEED

LOCA TED ON
BOTTOM SI DE OF
OUTPUT STUD

LOCA TED IN P. C. BO ARD
COMPARTMENT

LOCATED ON
CASE BACK

N.C.

N.C.

MOTOR

G

EA

RBOX

LOCA TED ON
MACHI NE' S
LEFT REAR

LOCA TED ON
CASE B ACK
WI TH RE AR
TO FRONT
AIRFLOW

LOCA TED ON
MACHI NE' S FRO NT
LEFT MIDWA Y

F

AN I

S CONT

INUO

USL

Y

ON

WHE

N POWER

SWITCH IS

ON

MO

VEDTO CONTROL

BO

ARD

ON CODE 1

109

9

AND HIGHER

+

-

+

LOCA TED ON BASEOF
FEEDE R COMP ARTM ENT

MOLD

ED
OUTPUT
STU

DS

40

VDC

14J1

10J1

CONTROL
BOARD
POWER

ON CODE 1

109

9 AND

HIGHER

FRONT OF DRI VE
ROLL AREA

LOCA TED INSIDE OF
P.C. BOARD COMPARTMENT

FRON T LEFT

RATED @ 300 A

OHMS = 1 0

LOCA TED INSIDE
OFP.C.BOARD
COMPARTMENT

BTO R

= 5TO6V

@ A

NY SPEED

BTO U

=

3.5

V @

ANY

SP

EED

1105A

1116B

1105B

1104C

1106C

1104D

6J5
3J5

1J5
5J5
4J5
2J5

MOT OR US E

SOLENOID/SPOOL
GUN DET ECT USE

GUN TRI GGER
USE

SPOOL GUN
DETECT SIGNAL

LOCA TED INSIDE
OF P.C. BOARD
COMPARTMENT

LOCAT ED INSIDE OF P. C.
BOARD COMPARTMENT

14J1

10J1

FROMX10

FROM

X9

RIGHT REAR
NEAR F AN

FRONT
TOP
LEFT

(TO PLEFTFRO NT O FWE LDER)

1J2
4J2

2J3

1J3

6J2

2J2

3J2

FOR ADDITIONAL
SPOOL GUN OPTI ONS/
ADAPTER PANEL
CONNECTI ONS
(SEEPAGE2)

1124

1117A

1123

5J2

1J6

3J6

1118

1117

TOROID
(1

TURN)

1117A

1118A

1118A

1123

1124

1122

1121

LOCA TED IN
MAGNUM 100 SG
READY ADA PTER
PANEL NEXT T O
WI RE DR I V E.

SWITCH SHOWN IN MAGNUM
100 PUSH GUN POSITION

326

327

SHOWS MAGNUM
PUSH GUN
INSTALLED

MAGNUM 100SG ADAPTER PANEL

6J14
16J14
12J14

2J14
14J14

6J1

100 SG
SPOOL GUN
DETECT

+

100 SG SPOOL
GUN MOTOR
USE

ONLY ON
EARLY CODES

G-3

Enhanced Diagram

SchEmaTic - cOmplETE machiNE - l12308-1 pG1

ElEcTrical DiaGramS

G-3

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

pOWEr miG® 215XT

J1

,

J1

4

CAVITY

NUM

BERING SEQUEN

CE

(

COMPONENT S

IDE OF P.C. BOARD

)

J2

J3

9

PA

J4 (TRIGGER,

T

ACH

OMETER,

MOT

ORSIDE)

8

16

1

4

6

1

3

8

1

4

5

1

2

4

6

1

3

(NON

-LEAD SIDE OF CON

NECTOR

)

LEAD

COLORCO

DE:

B-BL

ACK

G-GRE

EN
O-ORANGE
R-RE

D

U-BLU

E

W-WHIT

E

Y-Y

ELLO

W

COMPONENTVALUE U

NIT

S:

CAPA

CITOR: MFD/VOLTS

RESI

STO

R: OHMS/W

ATTS

CO

NNE

CTORPIN NUMBERS:

VIEW OFCONNECTOR ON PC BOARD

1

2

6

712

LATC

H

EX.12PIN CONNECTOR

LABELS:

COMM

ON

FRAME GROUND

EA

RTH

GROU

ND

L12308-1

POWER MIG

216

MACHINESCHEM

ATI

C

NO

NE

L12308

DO N

OT SCALE

THISD

RAW

ING

EQUIPMENTTYPE

:

SUBJEC

T:

UF

CRM41

566

2

PAGE___

OF

___

2

ENGINE

ERING CONTROLLED

MANUFACTURER:

No

T

HIS

DOC

UMENT CONTAINS PROP

RIETA

RY INFORMATIONOWNED BY LINC

OLN

GLOBAL, IN

C. AND MAY NOT BE DUPLICATED,C

OMMUNICATED

TO OTHER PARTIES ORUSEDFO

R A

NY PURP

OSE WIT

HOU

T THE EXPRESSWRITTE

N PE

RMISSIONOF LINCOLN

GLOBAL, IN

C.

PROPRIETARY &
CONFIDENTIAL:

REVISEDPAGE

2.

t

MAT

ERIAL TOLERANCE ("")

TO AGREE

WITH PUBLISHED

STANDARDS.

O

N ALL AN

GLES IS± .5

OF A

DEG

REE

ON 3 PLACEDECIM

ALSIS ±.002in.

(± 0.05

mm)

O

N 2

PLACE DEC

IMALS IS± .02 in. (± 0.5

mm)

U

NLESS

OTHERW

ISE

SPECIFIED

TOLERANCE

:

MANUFACTURING TOLERANCE PER

E2056

CHAN

GE DETAIL:

REFEREN

CE:

SCA

LE:

MATE

RIAL

DISPO

SITION:

APP

ROV

AL

DAT

E:

PROJECT
NU

MBE

R:

DOCUMENT
N

UMBER:

DOCUMENT
REVISION:

U

NITS:

IF

PRIN

TED

@A2 S

IZE

IN

CH

4/9/

2010

cstuble

T. S

PEAR

OBS

DRAWN

BY:

E

NGINEE

R:

CLEVELAND

APPROVE

D:

CONTROL:

C

L12308-1

2J3

122A

CONTROL

P.C. BOARD

(SCHEMATICG441

4)

G

ASSOLENOID -

1J3

123A

1J2

4J2

117A

120C

2J2

118A

LOCA TED ON
CASE B ACK

CONTROLS THE
FUNCT IONALITY OF
THEMACHI NE

3J5 3PB
6J5 6PB
1J5 1PB
5J5 5PB
4J5 4PB
2J5 2PB

V=8. 7VDC WHEN GAS IS FLOWING
COIL : 21 . 6 OHMS, 1 2VDC COI L

SPOOL GUN

GAS SOLENOID

LOCA TED ON
CASE B ACK

**

3J2

119A

6J2

106E

G

AS SOLENOID +

A
B

C
D
E
F

CLOSI NG GUN T RI GGER MAKES BOTH
THE STANDARDGUN AND T HE SPOOL
GUNS ELECT RI CALL Y

HO

T!

SPOOL

GUN

MOTOR

MOTO

R -

MOTO

R +

2.2VDC @ 50 I N/MIN
20V DC@ 700I N/MIN

LOCA TED ON
DIVI DER PANEL
INWIR EDR IVE
COMPARTMENT

105C
105D
116C

106D
104E

104F

104G

105E

6-PIN

AMPHENOL

K2703-1 SPOOL GUN

ADAPTER PANEL

(TOSW ITCH BETWEEN
SPOOL GUN AND
STANDARD GUN)

NORMALLY CLOSED ( SHOWN
INSPO OL GUNPOSITION)

S2
TOGGLE
SWITCH

REFE

R TO L11543-1 FOR SPOOL G

UN

ADA

PTER

PANELINSTALLATIO

N

IN

STRUCTIO

NS.

SPOOL GUN TRIGGER

SPOOL GUN PO T

11J1

12J1

.05

FROM STA NDARD
GUN TRI GGER

FROM11 2A FEED
MOT OR NEG L EAD

FROMSTANDARD GUN TRIGGER

16J1- POWE R TO STANDA RD GASSOLENOIDAND USED

FOR SPOOL GUN DETECT (AT CONTRO L BOARD)

MOTOR + SPEED CONTROL
FROMCONTROL BOARD

TO STANDARDFEED MO TOR

+40FROMDIODEDRIDGE

4J1 - TO CONTROLBOARD( TRIGGER)

THERM OSTAT

PTC

**

FOR MAGNUMSGAN

D MAGN

UM 250LX

SP

OOL G

UNS OPER

ATIO

N, REMOVE

MAGN

UM 100SG

ADAPTERPAN

EL (A

ND

HARNESS

/ SWITCH) FROM P5OF MACHI

NE

HARNESS AN

DPLUG IN

K2703-1 SPOOL G

UN

HARNESS

5J1

WFS

5K

POT

A

B

C

D

E

F

SPOOL

GUN

MOTOR

MOTO

R -

MOTO

R +

1.7VDC @ 50 IN/MIN
24VDC@ 700I N/MIN

7-PIN

AMPHENOL

SPOOL GUN T RIGGER

SPOOL GUN POT

16J14

129

6J14

128

2J14

14J14

125A

127A

12J14

G

126A

ALSO

SEE

PAGE

1

SENSING FOR 7 - PIN

SPOOL GUN T O

OPERAT E

REMOTE WFS

FOR 7-PI N

SPOOL GUN

MAX

TOROI

D

1 TOROIDON
B

OTH LE

ADS

S3

SPOOL GUN

SELECTOR

SWITCH

105F

119B

120B

104H

105G

SPOOL GUN

MOTOR

COMMON

WFS

100K

POT

MAX

REMOTE WFS

FOR 6-PI N

SPOOL GUN

SPOOL GUN

TRIGGER
COMMON

104G

THESST ANDARD FEED MOTOR CIRCUI T
ALSO I S USED FOR AL L THE SPOOL GUN
MOTORS WHEN SELEC TED WIT H
ADAPTER PANEL.

+

+

15J14

13J14

11J14

10J14

9J14

4J14

1J14

3J14

7J14

8J14

5J14

5J2

P

.M.

P

.M.

G-4

SchEmaTic - cOmplETE machiNE - l12308-1 pG2

ElEcTrical DiaGramS

G-4

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

pOWEr miG® 215XT

SOLENOID_DRIVE

CONTACTOR_DRIVE

SCLK

TRGR_INTRLK_EN

SPOOL_GUN_DETECT

PEAK_CUR_LIM

XRES

DATA

PSOC

ISENSE

VSENSE

TRIGGER

GAS_ON_OFF

COLD_INCH

GAS_PURGE

BURNBACK

SPEED_CTRL

INPUT_VOLTAGE

DRIVE_ON

BRAKE_ON

GAS_FLOW_ENABLE

2_4_OUT

SC_ISENSE

MOTOR_SELECT

SPOOL_SPOT

TACH_SIGNAL

COMMON

POSITIVE_15V

POWER_SUPPLY

POSITIVE_5V

PRIMARY_POSITIVE

COM

COM

+25-75VDC

+5V

COM

COM

+15V +5V

COM

COM

+5V

+5V

+15V

+25-75VDC

COM

COM

+5V

+15V

COM

+25-75VDC

COM

+5V

COM

+5V

COM

COM

+15V

COM

+15V

+15V

COM

+15V

COM

+5V

COM

+5V

COM

+5V

COM

+5V

COM

COM

+5V

+15V

COM

COM

+5V

COM

COM

+5V

COM

+5V

COM

COM

COM

COM

+5V

COM

+5V

COM

+15V

+15V

+5V

+15V

COM

COM

COM

+5V

COM

+5V

COM

COM

COM

7-10-2008

01

APM

145

30

37

4414-2G0

COMMON WIREDRIVE CONTROL

SCHEMATIC, CONTROL PCB

A

CRM_____

APM

G3850

03

--------

R-

PAGE OF

REVISION:

DOCUMENT

DOCUMENT
NUMBER:

NUMBER:

PROJECT

DATE:

APPROVAL

NA

DISPOSITION:

MATERIAL

SUBJECT:

EQUIPMENT TYPE:

PROPRIETARY & CONFIDENTIAL:

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

DRAWN BY:

ENGINEER:

APPROVED:

DESIGN INFORMATION

LAST NO. USED

C-

D-

DIODES =

ELECTRICAL SYMBOLS PER E1537

UNLESS OTHERWISE SPECIFIED)

RESISTORS = Ohms (

CAPACITORS =

MFD

GENERAL INFORMATION

(

UNLESS OTHERWISE SPECIFIED)

POWER SUPPLY SOURCE POINT

EARTH GROUND CONNECTION

(UNLESS OTHERWISE SPECIFIED)

COMMON CONNECTION

FRAME CONNECTION

SUPPLY VOLTAGE NET

LABELS

.022/50V

1/4W

1A,400V

HAVING A COMMON CODE NUMBER.

COMPONENTS OR CIRCUITRY OF CONTROLS

DIAGRAM MAY NOT SHOW THE EXACT

ABILITY OF A COMPLETE BOARD, THIS

WITHOUT AFFECTING THE INTERCHANGE-

PRINTED CIRCUIT BOARD MAY CHANGE

SINCE COMPONENTS OR CIRCUITRY ON A

G

REFERENCE:

J1

14

J1

6

J1

4

J1

11

J2

3

J1

2

J1

12

J2

4

J1

5

J3

2

J3

1

J1

16

J1

8

J1

7

J2

6

1

J1

J1

3

J1

13

J1

9

2

J2

1

J2

Q2

10A

100V

J1

15

J1

10

0.1uF

C17

50V

15

R68

D5
3A

200V

D6

1A/FR

400V

D7

1A

600V

D9
1A

600V

D10

1A

600V

D8
1A

600V

500

R72

3W

DZ2

5.1V

0.1W

332

R73

0.1W

221

R74

Q3

0.5A
40V

500

R71

3.32K

R75

1W

121

R76

1W

121

R77

1W

121

R78

1W

121

R79

0.1W

100K

R83

5W

0.2

R94

CY8C27443SX

X2

28

14

D12

3

2

1

0.2A
30V

D11

3

2

1

0.2A
30V

D13

21

3

0.2A
70V

D22

21

3

0.2A
70V

D21

21

3

0.2A
70V

Q11

0.115A
60V

Q10

0.115A
60V

Q5

0.5A
40V

Q6

0.5A
40V

OCI1

2

1

OCI1

6

4

5

S

MOV1

150V
80J

D17

3

12

0.2A
70V

9

J14

1

J14

14

J14

2

J14

12

J14

11

J14

16

J14

10

J14

4

J14

5

J14

7

J14

8

J14

13

J14

15

J14

D23

21

3

0.2A
70V

0.1W

100

R97

0.1W

100

R98

1

R100

1

R53

1

R99

1

R101

3

J14

5W

20

R95

0.1W

100K

R110

0.1W

100K

R109

Q14

0.115A
60V

224P

X3

14

13

12

224P

X3

7

6

5

224P

11

4

X3

224P

X3

1

2

3

0.1uF

C27

50V

3

12

D26

0.2A
70V

75K

R90

IR2118S

3

72

81

6

X4

IN

VB

HO

VS

VCC

COM

0.1W

200

R114

75K

R91

0.1W

3.32K

R93

0.1W

1.21K

R107

0.1W

2.21K

R84

0.1W

8.25K

R116

0.1W

750

R117

3

1

2

D27

0.2A
70V

75K

R113

10K

R51

0.063W

330pF

C26

100V

10K

R81

0.063W

10K

R82

0.063W

0.1uF

C13

50V

0.1uF

C16

50V

2

1

3

D18

0.2A
70V

0.1uF

C14

50V

3

1

2

D19

0.2A
70V

0.1uF

C15

50V

3

1

2

D20

0.2A
70V

0.1uF

C25

50V

2

1

3

D24

0.2A
70V

0.1uF

C18

50V

3

1

2

D16

0.2A
70V

J2

5

D29

12

3

0.2A
30V

10K

R54

0.063W

10K

R55

0.063W

D28

3

21

0.2A
30V

0.1W

100K

R125

0.1W

100K

R64

0.1W

1K

R121

0.1W

100K

R122

0.1W

100K

R123

0.1W

100K

R124

1K

R59

0.063W

1K

R63

0.063W

1K

R65

0.063W

1K

R56

0.063W

0.1uF

C12

50V

0.1uF

C23

50V

0.1uF

C22

50V

0.1uF

C19

50V

1K

R58

0.063W

1K

R105

0.063W

1K

R62

0.063W

1K

R112

0.063W

1K

R111

0.063W

0.1W

2.21K

R57

0.1W

2.21K

R106

0.1W

2.21K

R89

0.1W

2.21K

R88

0.1W

2.21K

R87

1K

R130

4.75K

R129

0.063W

1.82K
R131

1.82K
R96

1W

DZ4
18V

6

J14

Q15
10A

100V

0.1W

200

R133

10K

R134

0.063W

200

R136

0.1uF

C20

50V

0.1uF

C21

50V

0.1W

8.25K

R92

4.75K

R135

0.063W

0.1W

15K

R138

47pF

C30

50V

820pF

C33

50V

1

2

3

D30

0.2A
30V

LVC1G14GW

4

5

13

2X6AY

VCC

GNDNC

0.1W

10K

R139

0.1W

100K

R120

0.1W

100K

R86

0.1W

100K

R85

22.1K

R127

0.063W

0.1W

22.1K

R128

330pF

C32

100V

0.1W

1.21K

R132

0.1W

33.2K

R118

0.1W

16.5K

R137

0.1W

100

R115

511

R69

82uF

C34

35V

0.1uF

C1

50V

D31

1A/FR

400V

511

R70

47.5

R67

33.2K

R119

0.063W

0.1uF

C36

50V

0.1uF

C35

50V

1uF

C11

35V

600 OHMS

L2

600 OHMS

L1

224P

X3

8

9

10

FTP7

FTP6

FTP8

FTP9

0.1W

2.21K

R115

0.1W

301

R117

0.1W

43.2K
R137

0.1W

5.11K

R116

0.1W

90.9K

R118

R69

249

R70
249

R94

5W

0.1

Q8

60A

150V

PLANE1

Q9

60A

150V

Q4

60A

150V

Q7

60A

150V

GBPC3504W

D25

41

3

2

R144

100

R143

100

100

R142

R141

33.2

R140

33.2

C37

0.1uF
50V

TRI1
2500D

B1

R145

0.063W

10K

COM

G6057 1 , 2 , 4 & 5

TRI- 1

CLUSTER 3

FTP- 9

T- 1OCI- 1

MOV- 1 L- 2

Q- 15

X- 6

DZ- 4

THERMOSTAT INDICATOR LIGHT

17 P1(4)

USE J14 PIN 14 FOR 5V

GUN
TRIGGER

TRIGGR_INTRLK_EN

GAS FLOW ENABLE

GAS ON/OFF

COLD INCH

GAS PURGE

CY8C27443SX

PSOC

BRAKE_ON

DRIVE_ON

VSENSE

INPUT_VOLTAGE

TRIGGER INPUTS

MOTOR DRIVE

ASSEMBLY # G4415

TRIGGER

GUN

SPOOL

TOGGLE
SWITCH
IN SPOOL
GUN KIT

112A

112A

W

B

105A

MOTOR

GUN

SPOOL

MOTOR

MAIN

TOGGLE
SWITCH
IN SPOOL
GUN KIT

MAIN

SPOOL

GUN

SOLENOID

SOLENOID

CONTACTOR

TOGGLE
SWITCH
IN SPOOL
GUN KIT

MAIN
MOTOR
SPEED
SET POINT

CW

MAIN
WFS
POT

10K

CCW

100K

SPOOL
GUN
POT.
2 WIRE

HI-SIDE

LOW-SIDE

POWER SOURCE
OUTPUT ENABLE
WHEN CLOSED

4

2

POWER SOURCE
OUTPUT CONTROL

10K

CW

BURNBACK

PROGRAMMING

CONNECT TO
FILTERED DC

VOLTAGE

ISENSE

DIV BY 3

G4415 MULT BY 12

G4560 MULT BY 18

* USE J1-10 AND J1-14
TO CONNECT TO
28-42 VAC +/-20%.

* USE J1-6 AND J1-2
WHEN USING AN
EXTERNAL BRIDGE
RECTIFIER.

POWER TO CONTACTOR
AND SOLENOIDS.

USE J14 PIN 12 FOR COM

KEY

19

16 P1(2)

6 P2(5)

12 P1(3)

21 P2(2)

7 P2(3)

22 P2(4)

10 P1(7)

18 P1(6)

11 P1(5)

24 P0(0)

4 P0(1)

25 P0(2)

3 P0(3)

26 P0(4)

2 P0(5)

27 P0(6)

1 P0(7)

15

P1(0)

13

P1(1)

J1 PIN 6

20 P2(0)

8 P2(1)

23 P2(6)

5 P2(7)

CCW

10K

+10V

+5V

SPOT
TIME
POT.
3 WIRE

CALIBRATE

MOTOR_SELECT

+15V

CLUSTER 3

CLUSTER 3

ASSEMBLY No.

1 , 3 , 4 & 5

1 & 2

G4560

G4415

CLUSTER No.

CLUSTER 1

CLUSTER 3

CLUSTER 2

CLUSTER 3

CLUSTER 2

CLUSTER 2

CLUSTER 2

CLUSTER INFORMATION

CLUSTER 5

CLUSTER 3

CLUSTER 2

CONT

42VAC

CLUSTER 4

G-5

SchEmaTic - cONTrOl bD - G4414 pG1

ElEcTrical DiaGramS

G-5

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

pOWEr miG® 215XT

COM

02

7-10-2008

--------

03

A4414-2G0

CRM_____

SCHEMATIC, CONTROL PCB

COMMON WIREDRIVE CONTROL

APM

APM

---------

REFERENCE:

G

SINCE COMPONENTS OR CIRCUITRY ON A

PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGE-

ABILITY OF A COMPLETE BOARD, THIS

DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY OF CONTROLS

HAVING A COMMON CODE NUMBER.

1A,400V

1/4W

.022/50V

LABELS

SUPPLY VOLTAGE NET

FRAME CONNECTION

COMMON CONNECTION

(UNLESS OTHERWISE SPECIFIED)

EARTH GROUND CONNECTION

POWER SUPPLY SOURCE POINT

UNLESS OTHERWISE SPECIFIED)

(

GENERAL INFORMATION

MFD

CAPACITORS =

RESISTORS = Ohms (

UNLESS OTHERWISE SPECIFIED)

ELECTRICAL SYMBOLS PER E1537

DIODES =

_

_

_

D-

C-

LAST NO. USED

DESIGN INFORMATION

APPROVED:

ENGINEER:

DRAWN BY:

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

PROPRIETARY & CONFIDENTIAL:

EQUIPMENT TYPE:

SUBJECT:

MATERIAL
DISPOSITION:

NA

APPROVAL
DATE:

PROJECT
NUMBER:

NUMBER:

DOCUMENT

DOCUMENT
REVISION:

PAGE OF

R-

82uF

35V

C2

0.01uF
200V

C4

0.1W

100K

R22

150pF
100V

C6

2842AD8

8

2

74

6

5

3

1

X1

VREF

RT/CT

VFB

COMP

CS

VCC

OUT

GND

0.1W

2.21K

R23

0.0047uF
50V

C7

100pF
100V

C8

1.82K

R26

0.1W

5.11K

R28

33.2

R35

47.5

R41

47.5

R36

47.5

R37

47.5

R40

47.5

R42

47.5

R44

47.5

R46

47.5

R45

47.5

R43

0.0033uF
630V

C9

0.1W

1.5K

R48

1A

400V

D4

17A

200V

Q1

1.82K

R27

15W

T1

4

3

2

1

15W

T1

9

10

220uF

25V

C3

220uF

C5

25V

1

R31

1

R32

1

R33

1

R34

1W

20K

R29

43.2K
R30

0.1W

39.2K

R50

1.5K

R49

0.1W

301

R47

82uF

C31

35V

0.1uF

C29

50V

0.1uF

C28

50V

78M05C

X5

OUT

GND

IN

200

R38

200

R39

0.5W

DZ3
18V

1A

600V

D2
1A

600V

D3

100V

0.0018F

C10

C10

0.0033F
100V

PRIMARY_POSITIVE

COMMON

POSITIVE_15V

POSITIVE_5V

CLUSTER 2

CLUSTER 1

25-75VDC
OPERATION
OR 20-60VAC
OPERATION
(D25 REQ.)

+5V

0.5A

-DC_IN

+DC_IN

+15V

0.55A

CLUSTER 3

SEE PAGE 1

G-6

SchEmaTic - cONTrOl bD - G4414 pG2

ElEcTrical DiaGramS

G-6

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

pOWEr miG® 215XT

03

7-10-2008

APM

APM

SCHEMATIC, CONTROL PCB

COMMON WIREDRIVE CONTROL

03

A

CRM_____

4414-2G0

--------

---------

REFERENCE:

G

SINCE COMPONENTS OR CIRCUITRY ON A

PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGE-

ABILITY OF A COMPLETE BOARD, THIS

DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY OF CONTROLS

HAVING A COMMON CODE NUMBER.

1A,400V

1/4W

.022/50V

LABELS

SUPPLY VOLTAGE NET

FRAME CONNECTION

COMMON CONNECTION

(UNLESS OTHERWISE SPECIFIED)

EARTH GROUND CONNECTION

POWER SUPPLY SOURCE POINT

UNLESS OTHERWISE SPECIFIED)

(

GENERAL INFORMATION

MFD

CAPACITORS =

RESISTORS = Ohms (

UNLESS OTHERWISE SPECIFIED)

ELECTRICAL SYMBOLS PER E1537

DIODES =

_

_

_

D-

C-

LAST NO. USED

DESIGN INFORMATION

APPROVED:

ENGINEER:

DRAWN BY:

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

PROPRIETARY & CONFIDENTIAL:

EQUIPMENT TYPE:

SUBJECT:

MATERIAL
DISPOSITION:

NA

APPROVAL
DATE:

PROJECT
NUMBER:

NUMBER:

DOCUMENT

DOCUMENT
REVISION:

PAGE OF

R-

CY8C27443SX

X2

24

4

25

3

26

2

27

1

15

13

16

12 17

11

18

10

20

8

21

7

22

6

23

5

9

19

P0[0]

P0[5]

P0[6]

P0[7]

P0[4]

P0[3]

P0[2]

P0[1]

P1[0]

P1[1]

P1[2]

P1[3]

SMP

XRES

P1[5]

P1[7]

P1[6]

P1[4]

P2[3]

P2[2]

P2[1]

P2[0]

P2[5]

P2[7]

P2[6]

P2[4]

ISENSE

VSENSE

TRIGGER

GAS_ON_OFF

COLD_INCH

GAS_PURGE

BURNBACK

SPEED_CTRL

SPOOL_SPOT

INPUT_VOLTAGE

SPOOL_GUN_DETECT

2_4_OUT

GAS_FLOW_ENABLE

BRAKE_ON

DRIVE_ON

TRGR_INTRLK_EN

MOTOR_SELECT

SC_ISENSE

PEAK_CUR_LIM

XRES

SCLK

DATA

SOLENOID_DRIVE

TACH_SIGNAL

CONTACTOR_DRIVE

SEE PAGE 1

CLUSTER 1

THERMOSTAT INDICATOR LIGHT

CALIBRATE

G-7

SchEmaTic - cONTrOl bD - G4414 pG3

ElEcTrical DiaGramS

G-7

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NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

pOWEr miG® 215XT