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Lincoln Electric SVM189-B manual

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Table of contents for the manual

  • Page 1

    COMP A C T WIRE WELDERS SVM189-B January , 201 1 For use with machines having Code Numbers: 1 1 173 Thru 1 1506 and 1 1646 Thru 1 1650 LINCOLN ELECTRIC SER VICE MANUAL • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 888=935=3877 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.co[...]

  • Page 2

    COMP ACT WIRE WELDERS SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine of f 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. ______________[...]

  • Page 3

    SAFETY ii ii COMP ACT WIRE WELDERS 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 whi[...]

  • Page 4

    COMP ACT WIRE WELDERS SAFETY iii iii FOR ELECTRICALL Y 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 accordan[...]

  • Page 5

    SAFETY iv iv COMP ACT WIRE WELDERS 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 suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électr[...]

  • Page 6

    I I - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - COMP ACT WIRE WELDERS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 7

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 COMP ACT WIRE WELDERS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Machines in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 8

    INST ALLA TION A-2 A-2 COMP ACT WIRE WELDERS TECHNICAL SPECIFICA TIONS 180 Amp units INPUT – SINGLE PHASE ONL Y RA TED OUTPUT OUTPUT Standard V oltage/Frequency Input Current 230 V 60 Hz 20 Amps @ rated output 208 V 60 Hz 20 Amps @ rated output V oltage/Duty Cycle Current V oltage at Rated Amperes 230 V 30% 130 Amps 20 208 V 30% 130 Amps 17 Weldi[...]

  • Page 9

    INST ALLA TION A-3 A-3 COMP ACT WIRE WELDERS SELECT SUIT ABLE LOCA TION 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 of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block[...]

  • Page 10

    NOTE: Not all components are in every model. Check the Operator ’ s Manual for items included with a specific machine. • Wire Feeder W elder . or • W ork Cable & Clamp. • Handshield • Magnum 100L W elding Gun. • 3 .035” (0.9mm) Contact T ips (1 installed on the welding gun). • 3 .025” (0.6mm) Contact T ips. • Spool of .035?[...]

  • Page 11

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 COMP ACT WIRE WELDERS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Product Description & Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 12

    OPERA TION B-2 B-2 COMP ACT WIRE WELDERS COMMON WELDING ABBREVIA TIONS GMA W (MIG) • Gas Metal Arc Welding FCA W (Innershield or Outershield) • Flux Core Arc Welding PRODUCT DESCRIPTION (PRODUCT CAP ABILITIES) These small portable wire feed welders are capable of MIG welding on steel, stainless steel, and aluminum. They are also capable of flux[...]

  • Page 13

    OPERA TION B-3 B-3 COMP ACT WIRE WELDERS CONTROLS AND SETTINGS See Figure B.1 1. POWER SWITCH – T urns power on and off to the machine. 2. ARC VOL T AGE CONTROL – This knob sets the output voltage of the machine. Along with wire feed speed (WFS) this control sets a weld procedure. Refer to the procedure decal on the inside wire drive compartmen[...]

  • Page 14

    OPERA TION B-4 B-4 COMP ACT WIRE WELDERS See Figure B.3 8. WELDING GUN CONNECTOR BUSHING & THUMBSCREW – Provides electrical power to the welding gun. The thumbscrew holds the welding gun into the connector block. (Front of Machine, Side Door and Wire Drive Cover have been removed for clarity of Items 8 and 9). 9. OUTPUT TERMINALS – These co[...]

  • Page 15

    OPERA TION B-5 B-5 COMP ACT WIRE WELDERS T ABLE B.1 DRIVE ROLL AND WIRE GUIDES Wire Diameter & T ype .025”(0.6mm) MIG wire .030”(0.8mm) MIG wire .035”(0.9mm) MIG wire .030”(0.8mm) flux-cored .035”(0.9mm) flux-cored .045”(1.1mm) flux-cored Drive Roll .025”/.030” (0.6mm/0.8mm) Smooth Drive Roll .035”(0.9mm) Smooth Drive Roll .03[...]

  • Page 16

    OPERA TION B-6 B-6 COMP ACT WIRE WELDERS A. ITEMS NEEDED FOR FLUX CORED WELDING 1. 035”(0.9mm) Contact Tip 2. .025”-.035”(0.6mm-0.9mm) wire guide 3. Knurled Drive Roll 4. .035”(0.9mm) NR-21 1MP Flux-Cored Wire 5. Black Flux Cored gun nozzle 6. W elding Gun INNER WIRE GUIDE .025-.035 (.6-.9mm) .035 .035 NR-21 1 MP F L U X - C O R E W I R E 7[...]

  • Page 17

    OPERA TION B-7 B-7 COMP ACT WIRE WELDERS B. CONNECT LEADS AND CABLES ON THE MACHINE (See Figure B.7) 1. Open the case side door 2. Slide the connector end of the gun and cable through the hole in the machine front and into the gun connector bushing on the wire drive. 3. Make sure the gun connector end is seated fully into the wire drive and tighten[...]

  • Page 18

    OPERA TION B-8 B-8 COMP ACT WIRE WELDERS ( See Figure B.9) 9. Feed the wire through the wire drive inlet along the inner wire guide groove and into the wire drive outlet on the gun side. 10. Close the top drive roll pressure arm and secure by pivoting the tension adjustor back to the up position. 1 1. Re-install the outer wire guide. (See Figure B.[...]

  • Page 19

    OPERA TION B-9 B-9 COMP ACT WIRE WELDERS A. ITEMS NEEDED FOR MIG WELDING 1. 025”(0.6mm) Contact Tip 2. 025”-035”(0.6mm-0.9mm) Inner wire guide (140 180 amp machines) 3. .025”(0.6mm) Drive Roll 4. .025”(0.6mm) SuperArc L-56 Solid MIG Wire 5. Brass gun nozzle 6. W elding Gun .025 WIRE L-56 MIG 7. W ork Cable & Clamp 8. Gas Regulator &am[...]

  • Page 20

    OPERA TION B-10 B-10 COMP ACT WIRE WELDERS B. INST ALL SHIELDING GAS MIG welding requires an appropriate bottle of shielding gas. For mild steel either a cylinder bottle of Ar/CO 2 or 100% CO 2 can be used refer to the following instructions to properly connect shielding gas to the machine. CYLINDER may explode if dam- aged. Keep cylinder upright a[...]

  • Page 21

    OPERA TION B-11 B-11 COMP ACT WIRE WELDERS C. CONNECT LEADS AND CABLES ON THE MACHINE (See Figure B.14) 1. Open the case side door . 2. Slide the connector end of the gun and cable through the hole of the machine front and into the gun connector bushing on the wire drive. 3. Make sure the gun connector end is seated fully into the wire drive and ti[...]

  • Page 22

    OPERA TION B-12 B-12 COMP ACT WIRE WELDERS (See Figure B.16) 9. Feed the wire through the wire drive inlet along the inner wire guide groove and into the wire drive out- let on the gun side. 10. Close the top drive roll pressure arm and secure by pivoting the tension adjustor back to the up posi- tion. 1 1. Re-install the outer wire guide. (See Fig[...]

  • Page 23

    OPERA TION B-13 B-13 COMP ACT WIRE WELDERS 1. Follow the MIG welding steps in the previous sec- tion. 2. Connect a bottle of 100% Argon shielding Gas per previous section. 3. Disconnect Magnum 100L Gun. 4. Install optional K2532-1 Magnum 100SG spool gun per instructions included with gun. 5. Set Gun selector toggle switch to Spool Gun posi- tion. ([...]

  • Page 24

    NOTES B-14 B-14 COMP ACT WIRE WELDERS 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[...]

  • Page 25

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 COMP ACT WIRE WELDERS Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 26

    ACCESSORIES C-2 C-2 COMP ACT WIRE WELDERS K2525-1 - Spot T imer Kit T imer kit, when turned on, allows you to set a fixed weld time so that when the gun trigger is pulled the machine will weld for a fixed time period up to 10 sec- onds. Ideal for making consistent spot welds when welding on thin sheet metal K2528-1 - 045 Innershield Kit (For 230V m[...]

  • Page 27

    ACCESSORIES C-3 C-3 COMP ACT WIRE WELDERS 3-3/4" (95.3mm) 4"(102mm) 16"(406.4mm) 3-11/16" 8-1/16" 3-13/32" 9/32"(7.1mm) DRILL 3 PLACES 1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) 1/4"-20 X 1" Thread For mi ng Screw (1 Required) 1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) For mou[...]

  • Page 28

    ACCESSORIES C-4 C-4 COMP ACT WIRE WELDERS 2-15/16"(74.6mm) 3-3/16"(81mm) 7-9/16"(192.1mm) 1-1/2"(38.1mm) 13-1/2"(342.9mm) 1-1/4"(31.8mm) 9/32"(7.1mm) DR ILL 3 PLACES 1/4"-20 Flange Nut (2 Required) 1/4"-20 X 1" Thread For min g Screw (1 Required) 1/4"-20 X 1/2" Hex Head Cap Screw (2 Requir[...]

  • Page 29

    ACCESSORIES C-5 C-5 COMP ACT WIRE WELDERS TECHNICAL SPECIFICA TIONS - MAGNUM 100SG SPOOL GUN K2532-1 MODEL WELDING PROCESS WIRE ALLOYS WIRE SIZES (DIAMETERS) SPOOL SIZE RA TED WELDING CURRENT AND DUTY CYCLE OVERALL WEIGHT CABLE LENGTH OVERALL SIZE (BOUNDING BOX) METHOD OF GUIDANCE METHOD OF COOLING K2532-1 Magnum 100SG Spool Gun Aluminum GMA W (MIG[...]

  • Page 30

    ACCESSORIES C-6 C-6 COMP ACT WIRE WELDERS LOCA TING SPOOL GUN COMPONENTS AND FEA TURES (See Figure C.1 for Items 1 thru 6) 1. Gas Cone Assembly and Contact T ip. 2. Straightened Gun Tube Assembly . 3. 1/4-T urn Locking Collar . 4. T rigger Assembly . 5. Spool Cover: Provides easy , wide-open access to spool and wire drive. 6. Locking Knob: Captive [...]

  • Page 31

    ACCESSORIES C-7 C-7 COMP ACT WIRE WELDERS ASSEMBL Y OF ITEMS INSIDE THE MAGNUM SPOOL GUN 1. Liner Assembly feeds all specified wire. 2. Drive Roll: This Drive Roll feeds all specified wires. 3. Idle Roll Assembly: Non-adjustable tension setting for all specified wires 4. Incoming Wire Guide: Highly wear-resistant. 5. P6 Connector Control Leads: Mot[...]

  • Page 32

    ACCESSORIES C-8 C-8 COMP ACT WIRE WELDERS SAFETY PRECAUTIONS WELDING MACHINES • Read and understand the welding machine’ s instruction manual and all hazard warnings on equipment and in the manual. • Wear the proper personal protec- tive equipment for welding, includ- ing but not limited to, safety glass- es , h ea rin g p rot ect io n, we ld[...]

  • Page 33

    ACCESSORIES C-9 C-9 COMP ACT WIRE WELDERS 5. Remove screws from cover . ( A) is the location of two 3/4” long screws. 6. Remove cover . 7. If machine has a plastic handle (A) , then remove screw (B) . SPOOL GUN / WIRE DRIVE SELECT OR SWITCH INST ALLA TION 1. Install the M21 182 electrical adapter harness that came with the spool gun per the follo[...]

  • Page 34

    ACCESSORIES C-10 C-10 COMP ACT WIRE WELDERS ELECTRICAL CONNECTIONS 8. Adapter harness. All 6 connections shown are used, and each one is unique. (Proceed as follows) 9.A. Remove P3 (10-pin) from board J3 (10-pin). 9.B. Connect P3 (10-pin) to harness J7 (10-pin). 10. Connect harness P7 (10-pin) to board J3 (10- pin). IF MACHINE DOES NOT HA VE OPTION[...]

  • Page 35

    C-11 C-11 COMP ACT WIRE WELDERS ACCESSORIES 1 1.D. Find assembled pair of machine terminals (leads 543A & 544A) and disconnect. Go to step 13. IF MACHINE DOES HA VE OPTIONAL SPOT TIMER. (12.A. thru 12.D.) 12.A. Remove P5 (6-pin) from spot timer harness J9 (6-pin). 12.B. Connect P5 (6-pin) to adapter harness J8 (6- pin). 12.C. Connect adapter ha[...]

  • Page 36

    ACCESSORIES C-12 C-12 COMP ACT WIRE WELDERS MOUNTING THE SWITCH 15. Remove the plug button from the panel hole. 16. Plug button is no longer needed. Discard. 17, Remove mounting nut from switch. Keep mount- ing nut for installation. 18. Install switch into panel hole. Ensure washer tab is fully seated into smaller hole. 19. Reinstall mounting nut o[...]

  • Page 37

    ACCESSORIES C-13 C-13 COMP ACT WIRE WELDERS ROUTINE WELDING MACHINE PREP ARA TION ELECTRIC SHOCK CAN KILL. 1. Disconnect input power to the machine. ------------------------------------------------------------------------ 2. Machine polarity setting: Set to DC electrode posi- tive polarity per the machine’s Instruction Manual. 3. Gas selection [...]

  • Page 38

    ACCESSORIES C-14 C-14 COMP ACT WIRE WELDERS 5. Cut off bent end of wire, leaving straight section. 6. Gently pull open the idle roll assembly to expose the drive roll groove. FIGURE C.8 FIGURE C.9 FIGURE C.10 4. Extend approximately 12 inches of wire from spool. Straighten it out by back-bending it. Use care to prevent the wire from dereeling. 2. R[...]

  • Page 39

    ACCESSORIES C-15 C-15 COMP ACT WIRE WELDERS 8. While holding open the idle roll, slide end of wire through drive roll’ s groove and toward gun tube liner . 9. Slide the wire into the liner until it extends approxi- mately 1 inch beyond the end of the gas diffuser . Release idle roll tab without snapping it. FIGURE C.1 1 FIGURE C.12 FIGURE C.13 7.[...]

  • Page 40

    C-16 C-16 COMP ACT WIRE WELDERS ACCESSORIES CONNECTING THE GUN TO THE WELDING MACHINE 1. Disconnect input power to the machine. 2. Make sure that the gun locking knob is loosened. (See Figure C.20). 13. Reinstall spool cover . 1: tuck cover ’s tab in place at arrow and hold with thumb. 2: swing cover closed. 3: finger-tighten locking knob. 4: che[...]

  • Page 41

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 COMP ACT WIRE WELDERS Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 42

    MAINTENANCE D-2 D-2 COMP ACT WIRE WELDERS MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside thr Compact Wire Welders. Use only grounded receptacle. Do not touch electrically “hot” parts inside the machine. • Have qualified personnel do the mainte- nance an[...]

  • Page 43

    MAINTENANCE D-3 D-3 COMP ACT WIRE WELDERS GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor . Remove the contact tip from the gun. Using low pre[...]

  • Page 44

    MAINTENANCE D-4 D-4 COMP ACT WIRE WELDERS GUN HANDLE P ARTS The gun handle consists of two halves that are held together with a collar on each end. T o open up the han- dle, turn the collars approximately 60 degrees counter- clockwise until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are difficult to turn, pos[...]

  • Page 45

    MAINTENANCE D-5 D-5 COMP ACT WIRE WELDERS MAJOR COMPONENT LOCA TIONS 5 5 3 3 2 2 1 1 4 4 1. Case Front, Back and Bottom Assembly 2. Power Module Assembly 3. Center Panel Assembly 4. Wire Drive Assembly 5. Wraparound & Door Assembly Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur[...]

  • Page 46

    MAINTENANCE D-6 D-6 COMP ACT WIRE WELDERS MAJOR COMPONENT LOCA TIONS 1. Case Front Assembly 2. Wire Drive Assembly 3. Center Panel Assembly 4. Power Module and Base Assembly 5. Wraparound & Door Assembly 5 5 4 4 1 1 2 2 3 3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Mas[...]

  • Page 47

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 COMP ACT WIRE WELDERS Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 48

    THEOR Y OF OPERA TION E-2 E-2 COMP ACT WIRE WELDERS GENERAL DESCRIPTION The Compact Wire Welders that are covered by this manual are Constant V oltage (CV) DC welders that can be used for MIG or Flux-Core process . The 120 V AC machines are rated for 90 amps, 19.5 volts, at 20% duty cycle. The 208 / 230 V AC machines are rated for 130 amps, 17 / [...]

  • Page 49

    THEOR Y OF OPERA TION E-3 E-3 COMP ACT WIRE WELDERS INPUT LINE VOL T AGE, F AN MOTOR & MAIN TRANSFORMER A circuit breaker is incorporated in the circuit to protect the unit from current overloads. The main transformer receives the primary voltage from the Control Board and changes that high voltage and low current input power to a low voltage a[...]

  • Page 50

    THEOR Y OF OPERA TION E-4 E-4 COMP ACT WIRE WELDERS OUTPUT CONTROL, RECTIFICA TION & VOL T AGE FEEDBACK The AC voltage that is applied to the main transformer primary is controlled at the control board by two SCRs (Silicon Controlled Rectifiers). The SCRs are controlled by a pulse signal developed on the control board. The control board compare[...]

  • Page 51

    THEOR Y OF OPERA TION E-5 E-5 COMP ACT WIRE WELDERS TRIGGER, GAS SOLENOID AND WIRE DRIVE Closure of the trigger circuit (pulling the gun trigger) signals the control board to start several functions. A DC is applied to the gas solenoid (if present) to allow shielding gas to flow if required. The SCRs are acti- vated and voltage is applied to the ma[...]

  • Page 52

    THEOR Y OF OPERA TION E-6 E-6 COMP ACT WIRE WELDERS SCR OPERA TION A silicon controlled rectifier (SCR) is a three terminal device used to control large currents to a load. An SCR acts very much like a switch. When it is turned on, there is current flow from anode to cathode. In the ON state, the SCR acts like a closed switch. When the SCR is turne[...]

  • Page 53

    THEOR Y OF OPERA TION E-7 E-7 COMP ACT WIRE WELDERS THERMAL PROTECTION The Compact Wire Welders have a rated output duty cycle as defined in the T echnical Specification page. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a reasonable operating temperature. This is an automatic function of an[...]

  • Page 54

    NOTES E-8 E-8 COMP ACT WIRE WELDERS 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[...]

  • Page 55

    T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR F-1 F-1 COMP ACT WIRE WELDERS T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 56

    TROUBLESHOOTING & REP AIR F-2 F-2 COMP ACT WIRE WELDERS This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPT OM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms[...]

  • Page 57

    TROUBLESHOOTING & REP AIR F-3 F-3 COMP ACT WIRE WELDERS Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability[...]

  • Page 58

    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 ar e unable to perf orm t he test s/repairs safely , contact the Lincoln Electric Service Department for technical trou[...]

  • Page 59

    OUTPUT/FEEDING 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 ar e unable to perf orm t he test s/repairs safely , contact the Lincoln Electric Service Department for techni[...]

  • Page 60

    FEEDING 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 ar e unable to perf orm t he test s/repairs safely , contact the Lincoln Electric Service Department for technical tro[...]

  • Page 61

    WELDING PROBLEMS GAS FLOW 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 ar e unable to perf orm t he test s/repairs safely , contact the Lincoln Electric Service Department[...]

  • Page 62

    SPOOL GUN 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 ar e unable to perf orm t he test s/repairs safely , contact the Lincoln Electric Service Department for technical t[...]

  • Page 63

    SPOOL GUN 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 ar e unable to perf orm t he test s/repairs safely , contact the Lincoln Electric Service Department for technical t[...]

  • Page 64

    SPOOL GUN 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 ar e unable to perf orm t he test s/repairs safely , contact the Lincoln Electric Service Department for technical t[...]

  • Page 65

    Service and repair should be performed by only 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 thr[...]

  • Page 66

    LINCOLN ELECTRIC 5/16 Hex Head Screws on Models with Metal Handle 5/16 Hex Head on Models with Plastic Handle 3/4” Screws (2 Places) 2 Phillips Screws FIGURE F .1 – CASE REMOV AL CASE COVER REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) PROCEDURE 1. Disconnect power to the machine. 2. Remove the two(2) 5/16 hex-head screws from the top of the d[...]

  • Page 67

    Service and repair should be performed by only 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 thr[...]

  • Page 68

    G a s S o l e n o i d L e a d s FIGURE F .2 – GAS SOLENOID LOCA TION & LEADS GAS SOLENOID TEST (CONTINUED) TROUBLESHOOTING & REP AIR F-14 F-14 COMP ACT WIRE WELDERS PROCEDURE 1. Remove input power to the machine. 2. Perform the Case Cover Removal Procedure. 3. Locate the gas solenoid and lead connections. Do not disconnect the leads. See [...]

  • Page 69

    Service and repair should be performed by only 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 thr[...]

  • Page 70

    MO T - MOT+ FIGURE F .3 – PLUG P3 WIRE DRIVE MOT OR TEST (CONTINUED) TEST PROCEDURE NOTE: POLARITY MUST BE OBSER VED FOR THESE TESTS. T est for correct wire drive motor armature voltage. 1. Disconnect main input power to the machine. 2. Perform the Case Cover Removal Procedure . 3. Locate plug P3 on the wiring harness. See Wiring Diagram . Plug P[...]

  • Page 71

    MAIN TRANSFORMER TEST TROUBLESHOOTING & REP AIR F-17 F-17 COMP ACT WIRE WELDERS W ARNING Service and repair should be performed by only 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 safet[...]

  • Page 72

    1. Remove the input power to the machine. 2. Perform the Case Cover Removal Procedure . 3. Locate H1 and H2 on the control board terminal strips. See Wiring Diagram. 4. Place the voltage control to maximum. 5. T urn machine on and close trigger switch. ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. T urn the in[...]

  • Page 73

    MAIN TRANSFORMER TEST (CONTINUED) TROUBLESHOOTING & REP AIR F-19 F-19 COMP ACT WIRE WELDERS Secondary Lead (Secondary Lead on opposite side not shown) FIGURE F .4. – X1 & X2 LOCA TION 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 Retur[...]

  • Page 74

    NOTES F-20 F-20 COMP ACT WIRE WELDERS 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[...]

  • Page 75

    F AN MOT OR TEST TROUBLESHOOTING & REP AIR F-21 F-21 COMP ACT WIRE WELDERS Service and repair should be performed by only 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[...]

  • Page 76

    F AN MOT OR TEST (CONTINUED) TROUBLESHOOTING & REP AIR F-22 F-22 COMP ACT WIRE WELDERS 1. Remove the input power to the machine. 2. Perform the Case Cover Removal Procedure . 3. Locate the fan terminals on the Control board on terminal strip 1 and terminal strip 2. See Wiring Diagram . See Figure F .5. 4. T urn machine on to conduct voltage tes[...]

  • Page 77

    This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at machine output terminals. Positive probe to (=) terminal, negative probe to (-) terminal. SCOPE SETTIN[...]

  • Page 78

    This is NOT the typical voltage wave- form. The output capacitor was dis- connected from the circuit. Note the increased ripple in the waveform. This condition simulates the faulty output filter capacitor . Each vertical division represents 10 volts and that each hor- izontal division represents 20 millisec- onds in time. Note: Scope probes connect[...]

  • Page 79

    Service and repair should be performed by only 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 thr[...]

  • Page 80

    Control Board FIGURE F .6 – CONTROL BOARD LOCA TION CONTROL BOARD REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-26 F-26 COMP ACT WIRE WELDERS 1. Remove the input power to the machine. ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. Turn the input power OFF at the fuse box befor[...]

  • Page 81

    LINCOLN ELECTRIC Control Knob Nameplate Phillips Screws 5/64” Allen Set Screw FIGURE F .7 – SCREW/NUT LOCA TION(S) CONTROL BOARD REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-27 F-27 COMP ACT WIRE WELDERS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC[...]

  • Page 82

    NOTES F-28 F-28 COMP ACT WIRE WELDERS 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[...]

  • Page 83

    Service and repair should be performed by only 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 thr[...]

  • Page 84

    POWER MODULE REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-30 F-30 COMP ACT WIRE WELDERS 2 Phillips Screws 4 Phillips Screws (only found on 140c/180c models) Phillips Handle Mount Screw (only found on 140c/180c models) VIEWED FROM REAR OF MACHINE FIGURE F .8 – CASEBACK MOUNTING SCREWS 1. Disconnect main input powe[...]

  • Page 85

    POWER MODULE REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-31 F-31 COMP ACT WIRE WELDERS C e n t e r P a n e l S c r e w s O u t p u t S t u ds P o l a r i t y P a n e l C e n t e r P a n e l FIGURE F .9 – CENTER P ANEL SCREW REMOV AL Return to Section TOC Return to Section TOC Return to Section TOC Return to Sect[...]

  • Page 86

    NOTES F-32 F-32 COMP ACT WIRE WELDERS 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[...]

  • Page 87

    Service and repair should be performed by only 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 thr[...]

  • Page 88

    L o c k i n g T a bs 3 / 8 ” B o l t e d L e a d ( o pp o s i t e s i d e no t s h ow n ) FIGURE F .10 – LOCKING T ABS RECTIFIER, TRANSFORMER, CHOKE ASSEMBL Y & CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-34 F-34 COMP ACT WIRE WELDERS 1. Remove the input power to the machine. 2. Perform the Cas[...]

  • Page 89

    D o w C o r n i n g 3 4 0 ( App l y t o a r e a , o pp o s i t e s i d e n o t s h o w n) ) FIGURE F .1 1 – DOW CORNING 340 RECTIFIER, TRANSFORMER, CHOKE ASSEMBL Y & CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) 8. When re-installing the capacitor , make sure that the polarity is NOT reversed. See Figure F .12. 9. Clean the termi[...]

  • Page 90

    L o c k i n g T a b I n s e r t s N u t L o c k W a s h e r P l a i n W a s he r D o w Co r n i n g 3 4 0 ( a pp l y t o c on t a c t s u r f a c e s o n bo t h t e r m i n a l s ) FIGURE F .12 – DOW CORNING APPLICA TION AREAS RECTIFIER, TRANSFORMER, CHOKE ASSEMBL Y & CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TRANSFORMER AND [...]

  • Page 91

    T ransformer FIGURE F .13 – DOOR REMOV AL RECTIFIER, TRANSFORMER, CHOKE ASSEMBL Y & CAP ACIT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-37 F-37 COMP ACT WIRE WELDERS 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[...]

  • Page 92

    NOTES F-38 F-38 COMP ACT WIRE WELDERS 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[...]

  • Page 93

    Service and repair should be performed by only 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 thr[...]

  • Page 94

    LINCOLN ELECTRIC Control Knob Nameplate Phillips Screws 5/64” Allen Set Screw FIGURE F .14 – CASEFRONT KNOB REMOV AL WIRE DRIVE MOT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-40 F-40 COMP ACT WIRE WELDERS 1. Remove the input power to the machine. 2. Perform the Case Cover Removal Procedure . ELECTRIC SHOCK[...]

  • Page 95

    3 Phillips Mounting Screws FIGURE F .15 – WIRE DRIVE MOT OR WIRE DRIVE MOT OR REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-41 F-41 COMP ACT WIRE WELDERS 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 [...]

  • Page 96

    NOTES F-42 F-42 COMP ACT WIRE WELDERS 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[...]

  • Page 97

    Service and repair should be performed by only 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 thr[...]

  • Page 98

    2 Phillips Screws 4 Phillips Screws (only found on 140c/180c models) Phillips Handle Mount Screw (only found on 140c/180c models) VIEWED FROM REAR OF MACHINE FIGURE F .16 – CENTER P ANEL/F AN MOUNTING SCREW LOCA TION F AN MOT OR ASSEMBL Y REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) TROUBLESHOOTING & REP AIR F-44 F-44 COMP ACT WIRE WELDERS [...]

  • Page 99

    C e n t e r P a n e l S c r e w s C e n t e r P a n e l FIGURE F .17 – CENTER P ANEL MOUNTING SCREWS F AN MOT OR ASSEMBL Y REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) 6. Remove the appropriate wiring and gas hose from the top of the Power Module Chassis. Pliers may be necessary . 7. Remove the flathead mounting screws from the center panel. Se[...]

  • Page 100

    L o c k i n g T a bs F a n FIGURE F .18 – LOCKING T ABS & F AN F AN MOT OR ASSEMBL Y REMOV AL AND REPLACEMENT PROCEDURE (CONTINUED) 8. Depress the locking tabs and remove the top Power Module Chassis. See Figure F .18. 9. Label and disconnect any necessary leads attached to the Fan. 10. Remove the fan from the machine. 1 1. Upon installation [...]

  • Page 101

    RETEST AFTER REP AIR (140 AMP UNITS) TROUBLESHOOTING & REP AIR F-47 F-47 COMP ACT WIRE WELDERS Input V olts/Hertz Maximum Idle Amps Maximum Idle Watts 120/60 4.50 325 9-33 VDC OPEN CIRCUIT VOL T AGE INPUT IDLE AMPS & W A TTS 50-500 in./min. (1.3-12.7 m/min) WIRE SPEED RANGE RETEST AFTER REP AIR (125 AMP UNITS) Input V olts/Hertz Maximum Idl[...]

  • Page 102

    TROUBLESHOOTING & REP AIR F-48 F-48 COMP ACT WIRE WELDERS RETEST AFTER REP AIR (180 AMP UNITS) Input V olts/Hertz Maximum Idle Amps Maximum Idle Watts 230/60 2.50 275 9-33 VDC OPEN CIRCUIT VOL T AGE INPUT IDLE AMPS & W A TTS 50-500 in./min. (1.3-12.7 m/min) WIRE SPEED RANGE Return to Section TOC Return to Section TOC Return to Section TOC R[...]

  • Page 103

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 COMP ACT WIRE WELDERS Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram - (M20410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 104

    ElEcTrical DiaGramS G-2 cOmp acT WirE WElDErS WiriNG DiaGram - cOmplETE machiNE - (m20410) N.C. CAVI TY NUMBERI NG SEQUENCE VI EWED FROM I NSERTI ON SIDE OF CONNECTO RS. TO GR OUN D PER NA TI ONAL ELECT RICAL CODE. GUN X1 X2 T1 TRANS - FORMER OUTPUT CHOKE N.A. CAP- LOCATE D I N T RANSFO RMER CAP+ MOTOR SPOOL G UN (OP TION AL) THE RMO STAT TMP WI RE[...]

  • Page 105

    ElEcTrical DiaGramS G-3 cOmp acT WirE WElDErS WiriNG DiaGram - SpOOl GuN iNTErf acE OpTiON - (m20410-1) N.C . CAV IT YN U M B E R I N GS E Q U E N C EV I E W E D F ROM I NSER TI ON SIDE O F CONNECT ORS. MO TOR SPOOL GUN TS 1 R1 10 9 8 7 6 5 4 3 2 1 FA N 4 3 2 1 LA TCH N.B . WOR K AND GU N CONN EC TI ONS SH OWN F OR GMAW WELDING. ELECT RICAL SYMBO L[...]

  • Page 106

    ElEcTrical DiaGramS G-4 cOmp acT WirE WElDErS WiriNG DiaGram - cOmplETE machiNE - cODE 1 1444 ONl y - (m20410-2) N.C. CAVITY NUMBERING SEQUEN CE VIEWED FROM INSERTION SIDE OF CONNECTOR S. TO E ARTH GRO UND P ER NAT IONAL , LOCAL OR OTHER AP PL ICA BL E EL ECTRI CAL CO DES . GUN X1 X2 T1 TRA NS - FOR MER OUTPUT CHOKE N.A. CAP- LOCATE D I N T RANSFO [...]

  • Page 107

    ElEcTrical DiaGramS G-5 cOmp acT WirE WElDErS WiriNG DiaGram -cOmplETE machiNE - cODE 1 1442 ONl y - (m20410-3) SPOT T IMER M20 961 -2 N.C . CAVI TY NUM BE RI NG SEQUENCE VI EWE D FRO M INSERT ION SI DE OF CONNECTOR S. TO E ARTH GRO UND P ER NAT IONAL , LOCAL OR OTHER AP PL ICA BL E EL ECTRI CAL CO DES . (G REEN/Y ELL OW L E AD ) GUN X1 X2 T1 TRA N[...]

  • Page 108

    ElEcTrical DiaGramS G-6 cOmp acT WirE WElDErS SchEma Tic - cOmplETE machiNE m21240 2 7 CONNE CT O R PI N N UM BER S: CAPA CIT O R: MF D/ V OLT S 12 C OM PONE NT V AL U E U NIT S: LABELS : FR AM E GROUND 1 C OMM ON LE A D C OL O R COD E: VIEW OF CONNEC TO RO NP CB O A R D RE SI ST O R: O HM S/ W ATT S 6 EX. 12 PIN CONNEC TO R B- BL ACK G- GREEN O- O[...]

  • Page 109

    ElEcTrical DiaGramS G-7 cOmp acT WirE WElDErS SchEma Tic - machiNES WiTh vOl T aGE cONTrOl SWiTch - (G4741-1) G-7 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC[...]

  • Page 110

    ElEcTrical DiaGramS G-8 cOmp acT WirE WElDErS SchEma Tic - machiNES WiTh cONTiNuOuS vOl T aGE cONTrOl (G4822-1) G-8 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master T[...]

  • Page 111

    ElEcTrical DiaGramS G-9 cOmp acT WirE WElDErS SchEma Tic - fil TEr pc bOarD aSSEmbl y - (S24206-2) G-9 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. 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 [...]