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OUTPUT PROBLEMS
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
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.
CAUTION
Output voltage and wire feed speed
is present when the gun trigger is
NOT activated.
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 for “shorts” in the trigger
circuitry within the Power MIG®
215XT machine. See the
Wiring Diagram.
2. The control board may be faulty.
The machines output is low. Welds
are “cold”. The weld beads are
rounded or “humped” demonstrat-
ing poor wetting into the plate. The
machine cannot obtain full rated
output of 200 amps at 22VDC.
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 cor-
rect 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 connec-
tions.
1. Check for loose or faulty con-
nections 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 connec-
tions 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.
3. The output selector switch may
be faulty. Check for good con-
tact 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.
The output voltage is continuous
when the gun trigger is NOT acti-
vated. The wire feed functions nor-
mally.
1. The output contactor may be
stuck closed.
1. Perform the Output Contactor
Test.
TROUBLESHOOTING AND REPAIR
F-6 F-6
Power MIG® 215XT
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