SVM189-B
January, 2011
COMPACT WIRE WELDERS
and
11646 Thru 11650
For use with machines having Code Numbers: 11173 Thru 11506
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
LINCOLN
ELECTRIC
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888=935=3877 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
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ii
ii
SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
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.
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.
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.
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.
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:
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
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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 ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
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.
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 expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
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.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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.
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.
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SAFETY
WELDING and CUTTING
SPARKS can cause fire or
explosion.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
6.a. Remove fire hazards from the welding area.If
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 adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
regulators designed for the gas and
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.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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 though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
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.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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.
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.h. Also see item 1.c.
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.
COMPACT WIRE WELDERS
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SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque d’incendie dû aux étincelles.
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:
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.
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 met-
allique 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 defonc-
tionnement.
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.
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.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
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.
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.
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 debranch-
er à l’interrupteur à la boite de fusibles.
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, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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.
COMPACT WIRE WELDERS
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I
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
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 . . . . .Please refer to Service Navigator Parts Section for correct machine parts info.
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A-1
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Machines in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
MACHINES COVERED BY THIS MANUAL
CODE
11173
11175
11254
11255
11256
11257
11300
11302
11303
11304
11440
11441
11442
K-NUMBER
K2480-1
K2481-1
K2470-1
K2471-1
K2472-1
K2473-1
K2479-1
K2513-1
K2514-1
K2515-1
K2658-1
K2659-1
K2661-1
K2668-1
K2688-1
K2689-1
K2696-1
K2697-1
K2698-1
K2699-1
K2481-1
K2515-1
K2659-1
K2689-1
K2698-1
PRODUCT NAME
PRO-MIG 140T
PRO-MIG 180T
POWER MIG 140T *
POWER-MIG 140C
POWER MIG 180T *
POWER MIG 180C
PRO-CORE 125T
WELD-PAK 125HD
WELD-PAK 140HD
WELD-PAK 180HD
MIG-PAK 140
MIG-PAK180
POWER-MIG 180C
11444
11501
11502
11503
11504
11505
11506
11646
11647
11648
11649
11650
POWER-MIG 180C
SP140T
SP180T
EASY-CORE 125
EASY-MIG 140
EASY-MIG 180
WORK-PAK 125
PRO MIG 180
WELD-PAK 180HD
MIG PAK 180
SP180T
EASY-MIG180
* Discontinued Models
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A-2
A-2
INSTALLATION
180 Amp units
TECHNICAL SPECIFICATIONS
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency
230 V
208 V
Input Current
20 Amps @ rated output
20 Amps @ rated output
60 Hz
60 Hz
RATED OUTPUT
Voltage/Duty Cycle
230 V 30%
208 V 30%
Current
130 Amps
130 Amps
Voltage at Rated Amperes
20
17
OUTPUT
Open Circuit Voltage
34 V
Welding Current Range
30-180 Amps
Wire Speed Range
50 - 500 in/min.
(1.3 - 12.7 m/min.)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or Breaker Size1
Input Voltage/Frequency
Input Amps
Power Cord
230 V 60 Hz
40 Amp Super Lag
20
50 Amp, 250 V,
Three Prong Plug
(NEMA Type 6-50P)
PHYSICAL DIMENSIONS
Width
10.15 in
258 mm
Height
14.0 in
357 mm
Depth
18.6 in
472 mm
Weight
66 Ibs
30 kg
1 If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.
TECHNICAL SPECIFICATIONS 140 Amp units
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency
120 V / 60 Hz
Input Current
20 Amps @ rated output
RATED OUTPUT
Duty Cycle
20% Duty Cycle
Current
90 Amps
Voltage at Rated Amperes
19.5
OUTPUT
Welding Current Range
30-140 Amps
Open Circuit Voltage
33 V
Wire Speed Range
50 - 500 in/min.
(1.3 - 12.7 m/min.)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Power Cord
Input Voltage/Frequency Fuse or Breaker Size1,2 Input Amps
Extension Cord
120 V 60 Hz 20 Amp 20
15 Amp, 125 V,
Three Prong Plug
(NEMA Type 5-15P)
3 Conductor # 12 AWG
2
(4mm ) or Larger
up to 50 ft.(15.2m)
PHYSICAL DIMENSIONS
Depth
Height
14.0 in
357 mm
Width
10.15 in
258 mm
Weight
58 Ibs
26.3 kg
18.6 in
472 mm
1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.
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A-3
A-3
INSTALLATION
TECHNICAL SPECIFICATIONS 125 Amp units
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency
120 V / 60 Hz
Input Current
20 Amps @ rated output
RATED OUTPUT
Duty Cycle
20% Duty Cycle
Current
90 Amps
Voltage at Rated Amperes
19
OUTPUT
Welding Current Range
30-125 Amps
Maximum-Open Circuit Voltage
33 V
Wire Speed Range
50 - 500 in/min.
(1.3 - 12.7 m/min.)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or Breaker Size1,2 Input Amps
Input Voltage / Frequency
Power Cord
Extension Cord
120 V 60 Hz
20 Amp 20
15 Amp, 125 V, 3 Conductor #12
AWG
2
Three Prong Plug
(NEMA Type 5-15P)
(4mm ) or Larger
up to 50 ft.(15.2m)
PHYSICAL DIMENSIONS
Width
10.15 in
258 mm
Height
13.7 in
347 mm
Depth
17.9 in
454 mm
Weight
48 Ibs
21.7 kg
1
2
If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.
Requirements For Maximum Output
In order to utilize the maximum output capability of
the machine, a branch circuit capable of 25 amps at
120 volts, 60 Hertz is required.
Read entire installation section before starting
installation.
SELECT SUITABLE 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 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
air passages and cause overheating.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
STACKING
• Only personnel that have read and under-
stood the machine’s Operating Manual
should install and operate this equipment.
Compact Wire Welders cannot be stacked.
TILTING
• Machine must be plugged into a recepta-
cle which is grounded per any national,
local or other applicable electrical codes.
Each machine must be placed on a secure, level sur-
face, directly or on recommended cart. The machine
may topple over if this procedure is not followed.
• The Machine power switch is to be in the
OFF (“O”) position when installing work
cable and gun and when connecting
power cord to input power.
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A-4
A-4
INSTALLATION
IDENTIFY AND LOCATE COMPONENTS
• .030” -.045” (0.8 - 1.1mm) Knurled Drive Roll
(Installed on Machine)
NOTE: Not all components are in every model.
Check the Operator’s Manual for items
included with a specific machine.
• Wire Feeder Welder.
.030
.045
or
• .025” -.035” (0.6 - 0.9mm) Inner Wire guide
• .035” -.045” (0.9 - 1.1mm) Inner Wire Guide
(Installed on Machine)
• Outer Wire Guide (Installed on Machine)
INNER WIRE GUIDE
INNER WIRE GUIDE
OUTER WIRE GUIDE
.025-.035 (.6-.9mm)
.035-.045 (.9-1.1mm)
• Work Cable & Clamp.
• Handshield
®
N
L
O
C
IN
L
IC
R
T
C
E
L
E
• Black Flux-cored Gasless Gun Nozzle (Installed on
Welding Gun)
• Magnum 100L Welding Gun.
• Brass MIG Gas Gun Nozzle
• 3 .035” (0.9mm) Contact Tips
(1 installed on the welding gun).
• 3 .025” (0.6mm) Contact Tips.
• 2”(51mm) Spindle Adapter (For 8”(203mm) Reel of
wire)
• Regulator
• Gas Hose
• Learn to Weld (LTW1 Manual)
• DVD
• Spool of .035” (0.9 mm) diameter NR-211MP
Innershield Flux-cored Wire.
• Spool of .025” (0.6 mm) diameter L-56 MIG Wire.
1 MP
NR-21
L-56 MIG
WIRE
REGULATOR
2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)
GAS HOSE
• .025”-.030” (0.6 - 0.8mm)
Smooth Drive Roll
• .035” (0.9mm)
Smooth Drive Roll
LTW1
"LEARN TO WELD"
DVD
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B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Controls & Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3/B-4
Load Wire Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Load Wire Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11
Setting up and making an Aluminum Weld using the optional Spool Gun . . . . . . . . . . . . . . . . . . . . . . . .B-13
COMPACT WIRE WELDERS
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B-2
B-2
OPERATION
PRODUCT DESCRIPTION (PRODUCT
CAPABILITIES)
Read entire operation section before oper-
ating the Compact Wire Welder.
These small portable wire feed welders are capable of
MIG welding on steel, stainless steel, and aluminum.
They are also capable of flux-cored welding on mild
steel.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
The term “MIG” stands for Metal Inert Gas welding and
requires a separate bottle of shielding gas to protect
the weld until it cools. Appropriate shielding gas based
on the type of material you are welding can be pur-
chased separately from your local welding gas distrib-
utor. MIG welding is ideal for welding on thinner and
clean materials when a very clean excellent cosmetic
looking weld is required. An example would be auto-
motive body panels.
• Always wear dry insulating
gloves.
------------------------------------------
FUMES AND GASES can be
dangerous.
Flux-cored Welding does not require separate shield-
ing gas to protect the weld since the welding wire has
special additives known as flux to protect the weld until
it cools. Flux-cored welding is ideal for medium to
thicker material and if welding on painted or rusty steel.
Flux-cored welding is also ideal in outdoor applications
where windy conditions might blow the MIG shielding
gas away from the weld. Flux-cored welding produces
a good looking weld but does not produce an excellent
weld appearance as MIG welding does.
• 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 contain-
ers.
Most machines include the necessary items to weld
with either the MIG or the flux-cored welding process
on steel. The 125 amp units will require the addition of
a ‘MIG Conversion Kit’ (K2526-1) for welding gas
shielded processes. To weld on stainless steel option-
al stainless steel welding wire can be purchased sepa-
rately. This machine can weld aluminum using
.035”(0.9mm) diameter 4043 aluminum welding wire.
Since aluminum welding wire is soft an optional alu-
minum spool gun is recommended for best results. A
welding Procedure Decal is located inside machine
door to help provide suggested settings for welding.
------------------------------------------
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protec-
tion.
------------------------------------------
COMMON WELDING ABBREVIATIONS
Observe all safety information through-
out this manual.
------------------------------------------------------------
GMAW (MIG)
• Gas Metal Arc Welding
FCAW (Innershield or Outershield)
• Flux Core Arc Welding
COMPACT WIRE WELDERS
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B-3
B-3
OPERATION
CONTROLS AND SETTINGS
See Figure B.1
FIGURE B.1
1. POWER SWITCH – Turns power on and off to the
machine.
2
2. ARC VOLTAGE 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
compartment door to set a correct welding proce-
dure based on type of material and thickness being
welded.
3
NOTE: The Arc Voltage Control will be either a contin-
uous control or a multi-position switch depend-
ing on the model.
1
3. WIRE FEED SPEED CONTROL (WFS) – The knob
sets the speed that the machine feeds wire. Along
with arc voltage control this control sets a weld pro-
cedure. Refer to the procedure decal on the inside
wire drive compartment door to set a correct welding
procedure based on type of material and thickness
being welded.
FIGURE B.2
See Figure B.2
4. GUN TRIGGER – Depress the trigger to activates
the wire drive to feed wire and energizes the output
of the machine. Depress the trigger to weld and
release the trigger to stop welding.
5c
5. WELDING GUN – Delivers wire and welding current
to the weld.
a. Gun Liner – wire travels through the liner from the
wire drive. The gun liner will feed .025” to .035”
(0.6mm to 0.9mm) wire. The 180A machine can
weld with .045”(1.1mm) wire if an optional
.045”(1.1mm) liner is installed in the gun.
5b
5a
.035"(0.9mm)
NR-211-MP
5
WIRE SPOOL
b. Contact Tip – provides electrical contact to the
wire.
c. Nozzle – When flux-cored welding the black noz-
zle protects the mounting threads on the gun.
When MIG welding the brass nozzle funnels the
shielding gas to the weld.
4
6
7
6. WORK CLAMP & CABLE – Clamps to the work
piece being welded and completes the electrical
welding circuit.
7. GUN TRIGGER CONNECTOR RECEPTACLE –
Plug the 4 pin gun trigger connector into this recep-
tacle.
COMPACT WIRE WELDERS
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B-4
B-4
OPERATION
See Figure B.3
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 connections allow
for changing the output polarity of the machine
depending on whether you are MIG welding (+) or
flux-cored welding (-)-.
8
9
FIGURE B.4
See Figure B.4
2"(51mm) SPINDLE ADAPTER (FOR 8"(20mm) REEL OF WIRE)
10. WIRE SPOOL SPINDLE AND BRAKE – Holds a
4”(102mm) diameter spool. Use the 2”(51mm)
spindle adapter included with the machine to use
8”(203mm) diameter spools. The wing nut sets the
brake friction to prevent the spool from over rotat-
ing when the trigger is released.
( 4"(102mm) REEL OF WIRE)
FIGURE B.5
See Figure B.5
11. WIRE DRIVE & COMPONENTS (ALUMINUM
DRIVE HOUSING) – Feeds wire from the wire
spool through the drive and through the welding
gun to the weld.
TOP DRIVE ROLL PRESSURE ARM
TENSION ADJUSTOR DOWN
WIRE SPOOL
.035" (0.9mm)
a. Top and Bottom Drive Roll – Drives the wire
through the drive system. The drive roll has a
groove to match the specific wire type and diam-
eter. Refer to Table B.1 for available drive rolls.
b. Inner & Outer Wire Guide – Guides the wire
between the Top and Bottom Drive Roll and
through the wire drive. The inner guide has a
groove to match a particular wire diameter. Refer
to Table B.1 for available wire guides.
c. Drive Roll Tension Thumbscrew – Turning
clockwise increases the force on the drive rolls
and turning counterclockwise decreases the
force.
NR-211-MP
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE GUIDE REMOVED
COMPACT WIRE WELDERS
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B-5
B-5
OPERATION
See Figure B.5a
FIGURE B.5a
11a. WIRE DRIVE & COMPONENTS (MOLDED
DRIVE HOUSING) – Feeds wire from the wire
spool through the drive and through the welding
gun to the weld.
PIVOT ARM ASSEMBLY
BEARING
OUTGOING GUIDE
TENSION ARM ASSEMBLY
a. Drive Roll – Drives the wire through the drive
system. The drive roll has a groove to match the
specific wire type and diameter. Refer to Table
B.1 for available drive rolls.
WIRE SPOOL
.035" (0.9mm)
b. Liner & Outgoing Guide – The liner guides the
wire between the bearing on the Pivot Arm
Assembly and Drive Roll and through the outgo-
ing guide.
NR-211-MP
LINER
c. Drive Roll Tension Thumbscrew – Turning
clockwise increases the force on the drive roll
and turning counterclockwise decreases the
force.
DRIVE ROLL
TABLE B.1
DRIVE ROLL AND WIRE GUIDES
Drive Roll Drive Roll Part Inner Wire Guide Inner Wire Guide
Wire Diameter &
Type
Number
KP2529-1
KP2529-2
KP2529-3
KP2529-3
Part Number
.025”(0.6mm) MIG wire .025”/.030” (0.6mm/0.8mm)
Smooth Drive Roll
.030”(0.8mm) MIG wire
.025”-.035”
(0.6mm-0.9mm)
Steel Wire Guide
.035”(0.9mm) MIG wire .035”(0.9mm) Smooth Drive Roll
KP2531-1
.030”(0.8mm) flux-cored .030”/.045” (0.8mm/1.1mm)
Knurled Drive Roll
.035”(0.9mm) flux-cored
.045”(1.1mm) Steel
Wire Guide
.045”(1.1mm) flux-cored
.030”/.045” (0.8mm/1.1mm)
Knurled Drive Roll
KP2531-2
See Figure B.6
FIGURE B.6
12. CIRCUIT BREAKER – If the rated input current of
the machine is exceeded this circuit breaker will
trip. Press to reset.
13
12
13. GAS INLET – Shielding gas connects to this inlet.
NOTE: Only on 125 amp machines that have added
the MIG Conversion Kit (K2525-1)
COMPACT WIRE WELDERS
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B-6
B-6
OPERATION
SETTING UP AND MAKING A FLUX-CORED WELD
A. ITEMS NEEDED FOR FLUX CORED
WELDING
7. Work Cable & Clamp
1. 035”(0.9mm) Contact Tip
NOTE:125 amp units come set up for flux cored wire
welding.
2. .025”-.035”(0.6mm-0.9mm) wire guide
INNER WIRE GUIDE
.025-.035 (.6-.9mm)
3. Knurled Drive Roll
.030
.045
4. .035”(0.9mm) NR-211MP Flux-Cored Wire
1 MP
.035 NR-21
5. Black Flux Cored gun nozzle
6. Welding Gun
COMPACT WIRE WELDERS
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B-7
B-7
OPERATION
LOCATE COMPONENTS
B. CONNECT LEADS AND CABLES ON
THE MACHINE
FIGURE B.7
TO CONNECT TO THE
FRONT OF MACHINE
CASE SIDE DOOR
(See Figure B.7)
1. Open the case side door
SLIDE
CONNECTOR
END HERE
OPEN LATCH 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.
TERMINAL END
(FITS ON STUD INSIDE
SEE FIGURE BELOW)
(4 PIN)
LEAD CONNECTOR
3. Make sure the gun connector end is seated fully
into the wire drive and tighten the thumbscrew to
secure the gun connector.
WORK CLAMP
ALL COMPONENTS SHOWN CONNECTED
(FRONT AND SIDE DOOR IS REMOVED
FOR CLARITY)
GUN AND CABLE
4. Plug the gun trigger lead connector into the 4 pin
gun trigger receptacle on the machine front.
SHORT POWER
CABLE NEGATIVE "-"
OUTPUT TERMINAL
5. Wire Drive Polarity. Flux cored welding requires
negative (-) polarity. Connect the short power cable
from the wire drive to the negative (-) output termi-
nal and tighten the thumbscrew.
THUMB SCREW TO
TIGHTEN CONNECTOR
BUSHING
CONNECTOR
END ATTACH
6. Work Lead Connection. Slide the lugged end of the
work cable through the hole in the machine front
and place on the positive (+) output terminal and
tighten thumbscrew.
WORK LEAD
CONNECTION
POSITIVE "+"
OUTPUT TERMINAL
(4 PIN)
TRIGGER RECEPTACLE
PLUGGED IN
WORK CLAMP
C. LOAD WIRE SPOOL
FIGURE B.8
(See Figure B.8)
1. Locate the blue labeled 4"(102mm) diameter
spool of .035”(0.9mm) NR-211MP flux-cored wire
and place onto wire spool spindle. Orient the
spool so that the wire feeds off the top of the
spool.
TOP DRIVE ROLL PRESSURE ARM
TENSION ADJUSTOR DOWN
2. Secure spool in place by tightening the wing nut
against the against the spacer that holds the wire
spool on the spindle.
WIRE SPOOL
.035" (0.9mm)
NR-211-MP
3. Open the top drive roll pressure arm by rotating
the tension adjustor arm down and pivoting the
drive roll pressure arm up.
4. Remove the outer wire guide.
INNER WIRE GUIDE REMOVED
4a. Slide gun out of drive slightly.
LOWER DRIVE ROLL REMOVED
5. Remove the lower drive roll and inner wire guide.
6. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.
7. Install the .030”/.045”(0.8mm/1.1mm) knurled lower drive roll.
OUTER WIRE
GUIDE REMOVED
8. Carefully unwind and straighten the first six inches of
welding wire from the spool. Do not let the end of
the wire go to prevent the wire from unspooling.
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B-8
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.
B-8
OPERATION
FIGURE B.9
(
TOP DRIVE ROLL
PRESSED AGAINST
LOWER DRIVE ROLL
TENSION ADJUSTOR
LOCKED IN POSITION
DIRECTION
OF WIRE
10. Close the top drive roll pressure arm and secure by
pivoting the tension adjustor back to the up position.
WIRE SPOOL
.035" (0.9mm)
SLIDE WIRE
INTO GUN
CONNECTOR
SIDE
NR-211-MP
11. Re-install the outer wire guide.
(See Figure B.10)
LOWER DRIVE ROLL
BE SURE WIRE
IS IN GROOVE
12. Remove the nozzle from the gun and contact tip and
straighten the gun out flat.
FIGURE B.10
13. Turn the machine power to on and depress the gun
trigger to feed the wire through the gun liner until the
wire comes out of the threaded end of the gun sev-
eral inches. (See figure B.11)
.035"(0.9mm)
NR-211-MP
REMOVED NOZZLE
14. When trigger is released spool of wire should not
unwind. Adjust wire spool brake accordingly.
REMOVED CONTACT TIP
WIRE SPOOL
LAY CABLE AND GUN STRAIGHTEN
IN THIS POSITION
WARNING
MOVING PARTS AND ELECTRICAL CON-
TACT CAN CAUSE INJURY OR BE FATAL.
•When the gun trigger is depressed drive
rolls, spool of wire and electrode are
ELECTRICALLY LIVE (HOT).
PLUG IN POWER
INPUT CORD
FIGURE B.11
• Keep away from moving parts and pinch
points.
• Keep all Doors, Covers, panels and
guards securely in place.
ON/OFF
SWITCH
DO NOT REMOVE OR CONCEAL WARN-
ING LABELS.
FEED WIRE
APPROXIMATELY 4.00"
FROM THE GUN TUBE END
.035"(0.9mm)
NR-211-MP
DEPRESS TRIGGER
TO ACTIVATE WIRE,
WHICH FEEDS THE WIRE
THRU THE LINER.
WIRE SPOOL
----------------------------------------------------------------------------
15. Install the .035”(0.9mm) contact tip
ROTATION
16. Install the black flux cored welding nozzle to the gun.
17. Trim the wire stickout to 3/8”(9.5mm) from the con-
tact tip. (See Figure B.12)
WORK CLAMP AND CABLE
18. Close the case side door. The machine is now ready
to weld.
FIGURE B.12
TRIM WIRE
STICKOUT
3/8"(9.5mm)
from the Contact Tip
INSTALL .035 CONTACT TIP
19. Read "Learn to Weld" (LTW1) that is included with
the machine or watch the "How to Weld" DVD includ-
ed with the machine.
INSTALL BLACK FLUX-CORED NOZZLE
20. Based on the thickness of the material you are going
to weld and the type and diameter of the welding
wire set the voltage and the wire feed speed per the
procedure decal attached to the inside of the wire
drive compartment door.
COMPACT WIRE WELDERS
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B-9
B-9
OPERATION
SETTING UP AND MAKING A MIG WELD
A. ITEMS NEEDED FOR MIG WELDING
1. 025”(0.6mm) Contact Tip
7. Work Cable & Clamp
2. 025”-035”(0.6mm-0.9mm) Inner wire guide (140
180 amp machines)
INNER WIRE GUIDE
.025-.035
8. Gas Regulator & Gas Line
5
25-.03
0
3. .025”(0.6mm) Drive Roll
9. Bottle of 75/25 Ar/CO shielding gas (or 100% CO
2
2
shielding gas) (note this requires a CO regulator
2
adapter which is sold separately.
4. .025”(0.6mm) SuperArc L-56 Solid MIG Wire
FEMALE END
MALE END
L-56 MIG
WIRE
CO2
100%
75/25
MIXES
5. Brass gun nozzle
(REQUIRES ADAPTERꢀ
SOLD SEPARATELY)
NOTE:125 amp units must be upgraded with a
MIG Conversion Kit (K2526-1).
6. Welding Gun
COMPACT WIRE WELDERS
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B-10
B-10
OPERATION
FIGURE B.13
B. INSTALL SHIELDING GAS
MALE END
MIG welding requires an appropriate bottle of shielding
REGULATOR
ADAPTER
gas. For mild steel either a cylinder bottle of Ar/CO or
S19298
2
PLASTIC
WASHER
CO2
100%
100% CO can be used refer to the following instructions
2
to properly connect shielding gas to the machine.
FEMALE END
75/25
MIXES
WARNING
CYLINDER may explode if dam-
aged. Keep cylinder upright and
chained to support
• Keep cylinder away from areas
where it may be damaged.
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench.
• Never lift welder with cylinder
attached.
NOTE: If connecting to 100% CO cylinder, a CO
2
regulator adapter (S19298) is required and must be
• Never allow welding electrode to
touch cylinder.
2
purchased separately. When using the CO adapter
2
• Keep cylinder away from welding
or other live electrical circuits.
be sure to install plastic washer included in the fitting
on the bottle side.(See Figure B.13 )
-----------------------------------------------------------------------
4. Refer to Figure B.13. Attach one end of inlet gas hose
to the outlet fitting of the flow regulator and tighten the
union nut securely with a wrench. Connect the other
end to the machine Solenoid Inlet Fitting (5/8-18
female threads — for CGA — 032 fitting). Make certain
the gas hose is not kinked or twisted.
WARNING
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply
when not in use.
SHIELDING GAS
1. For CO , open the cylinder very slowly. For argon-
2
1. Secure the cylinder to a wall or other stationary sup-
port to prevent the cylinder from falling over.
Insulate the cylinder from the work circuit and earth
ground. Refer to Figure B.13.
mixed gas, open cylinder valve slowly a fraction of a
turn. When the cylinder pressure gauge pointer stops
moving, open the valve fully.
2. Set gas flow rate for 30 to 40 cubic feet per hour (14
to 18 I/min.) under normal conditions, increase to as
high as 40 to 50 CFH (18 to 23.5 I/min.) under drafty
(slightly windy) conditions.
2. With the cylinder securely installed, remove the
cylinder cap. Stand to one side away from the out-
let and open the cylinder valve very slightly for an
instant. This blows away any dust or dirt which may
have accumulated in the valve outlet.
3. Keep the cylinder valve closed, except when using
the machine.
WARNING
BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE OUTLET WHEN “CRACKING” THE VALVE.
Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
stand to one side.
------------------------------------------------------------------------
COMPACT WIRE WELDERS
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B-11
B-11
OPERATION
FIGURE B.14
C. CONNECT LEADS AND CABLES ON
THE MACHINE
LOCATE COMPONENTS
TO CONNECT TO THE
FRONT OF MACHINE
(See Figure B.14)
1. Open the case side door.
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.
SLIDE
CONNECTOR
END HERE
OPEN LATCH DOOR
TERMINAL END
(FITS ON STUD INSIDE
SEE FIGURE BELOW)
3. Make sure the gun connector end is seated fully into
the wire drive and tighten the thumbscrew to secure
the gun.
(4 PIN)
LEAD CONNECTOR
WORK CLAMP
ALL COMPONENTS SHOWN CONNECTED
(FRONT AND SIDE DOOR IS REMOVED
FOR CLARITY)
4. Plug the gun trigger lead connector into the 4 pin
gun trigger receptacle on the machine front.
GUN AND CABLE
5. Wire Drive Polarity. MIG welding requires Positive
(+) polarity. Connect the short power cable from the
wire drive to the positive (+) output terminal and
tighten the thumbscrew.
WORK LEAD
CONNECTION
NEGATIVE "-"
THUMB SCREW TO
TIGHTEN CONNECTOR
BUSHING
OUTPUT TERMINAL
CONNECTOR
END ATTACH
6. Work Lead Connection. Slide the lugged end of the
work cable through the hole in the machine front and
place on the negative (-) output terminal and tight-
en thumbscrew.
SHORT POWER
CABLE POSITIVE "+"
OUTPUT TERMINAL
(4 PIN)
TRIGGER RECEPTACLE
PLUGGED IN
WORK CLAMP
D. LOAD WIRE SPOOL
(See Figure B.15)
1. Locate the green labeled 4"(102mm) diameter spool
of .025”(0.6mm) L-56 solid MIG wire and place onto
wire spool spindle. Orient the spool so that the wire
feeds off the top of the spool.
FIGURE B.15
2. Secure spool in place by tightening the wing nut
against the against the spacer that holds the wire
spool on the spindle.
TOP DRIVE ROLL PRESSURE ARM
TENSION ADJUSTOR DOWN
3. Open the top drive roll pressure arm by rotating the
tension adjustor arm down and pivoting the idle roll
pressure arm up.
WIRE SPOOL
.025" (0.6mm)
4. Remove the outer wire guide.
4a. Slide gun out of drive slightly.
5. Remove the lower drive roll and inner wire guide.
6. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.
7. Install the .025”(0.6mm) smooth grooved lower drive roll.
INNER WIRE GUIDE REMOVED
LOWER DRIVE ROLL REMOVED
OUTER WIRE
GUIDE REMOVED
8. Carefully unwind and straighten the first six inches
of welding wire from the spool. Do not let the end of
the wire go to prevent the wire from unspooling.
COMPACT WIRE WELDERS
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B-12
B-12
OPERATION
(See Figure B.16)
FIGURE B.16
TOP IDLER ROLL
PRESSED AGAINST
LOWER DRIVE ROLL
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.
TENSION ADJUSTOR
LOCKED IN POSITION
DIRECTION
OF WIRE
10. Close the top drive roll pressure arm and secure by
pivoting the tension adjustor back to the up posi-
tion.
WIRE SPOOL
.025" (0.6mm)
SLIDE WIRE
INTO GUN
CONNECTOR
SIDE
11. Re-install the outer wire guide.
(See Figure B.17)
12. Remove the nozzle and contact tip from the gun
and straighten the gun cable out flat.
DRIVE ROLL
BE SURE WIRE
IS IN GROOVE
13. Turn the machine power to on and depress the gun
trigger to feed the wire through the gun liner until
the wire comes out of the threaded end of the gun
several inches. (See Figure B.18)
FIGURE B.17
WIRE SPOOL
.025" (0.6mm)
14. When trigger is released the spool of wire should not
unwind. Adjust wire spool brake accordingly.
REMOVED NOZZLE
REMOVED CONTACT TIP
L
LAY CABLE AND GUN STRAIGHTEN
IN THIS POSITION
WARNING
MOVING PARTS AND ELECTRICAL
CONTACT CAN CAUSE INJURY OR BE
FATAL.
•When the gun trigger is depressed
drive rolls, spool of wire and electrode
are ELECTRICALLY LIVE (HOT).
• Keep away from moving parts and
pinch points.
FIGURE B.18
PLUG IN POWER
INPUT CORD
• Keep all Doors, Covers, panels and
guards securely in place.
ON/OFF
SWITCH
DO NOT REMOVE OR CONCEAL
WARNING LABELS.
FEED WIRE
APPROXIMATELY 4.00"
FROM THE GUN TUBE END
WIRE SPOOL
.025" (0.6mm)
DEPRESS TRIGGER
TO ACTIVATE WIRE,
WHICH FEEDS THE WIRE
THRU THE LINER.
-----------------------------------------------------------------------
15. Install the .025”(0.6mm) contact tip.
L
ROTATION
16. Install the brass gas MIG welding nozzle to the gun.
17. Trim the wire stickout to 3/8”(9.5mm) from the nozzle
end. (See Figure B.19)
WORK CLAMP AND CABLE
FIGURE B.19
18. Close the case side door. The machine is now ready
to weld.
TRIM WIRE
STICKOUT
INSTALL .025 CONTACT TIP
3/8"(9.5mm)
from the Brass Nozzle
19. Read "Learn to Weld" (LTW1) that is included with the
machine or watch the "How to Weld" DVD included
with the machine.
INSTALL BRASS NOZZLE
20. Based on the thickness of the material you are going
to weld and the type and diameter of the welding wire
set the voltage and the wire feed speed per the pro-
cedure decal attached to the inside of the wire drive
compartment door.
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B-13
B-13
OPERATION
SETTING UP AND MAKING AN ALUMINUM WELD USING
THE OPTIONAL SPOOL GUN
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. (See Figure B.20)
FIGURE B.20
6. Turn machine on and make weld per recommend-
ed settings on the Procedure Decal inside machine
door.
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B-14
B-14
NOTES
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C-1
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Welding Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5
Locating Spool Gun Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6
Items Inside the Spool Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7
Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-9
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-10/C-11
Loading Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-14/C-15
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C-2
C-2
ACCESSORIES
K2525-1 - Spot Timer Kit
Timer 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 models)
Includes everything needed to weld with .045”(1.1mm)
diameter
Innershield
wire.
Includes
an
.035”/.045”(0.9mm/1.1mm) Magnum™ 100L gun liner,
.045”(1.1mm) Contact Tip, gasless nozzle, knurled
drive roll, .045”(1.1mm) inner wire guide, and a 10 lb.
(4.5kg) spool of .045"(1.1mm) Innershield® NR®-212
wire.
K2532-1 - Magnum 100SG Spool Gun
Designed to easily feed small 4"(102mm0 diameter
(1lb.-.5kg spools of) .030”(0.8mm) or .035”(0.9mm)
aluminum wire. Includes gun, adapter kit, three extra
.035”(0.9mm) contact tips, gas nozzle, and spool of
Superglaze 4043 .035"(0.9mm) diameter welding wire.
Packaged in a convenient carry case.
K2377-1 - Small Canvas Cover
Protect your machine when not in use. Made from
attractive red canvas that is flame retardant, mildew
resistant and water repellent. Includes a convenient
side pocket to hold welding gun.
For additional Optional and Miscellaneous Parts
(See Parts Pages)
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C-3
C-3
ACCESSORIES
K520—Utility Cart
Heavy duty cart stores and transports welder, 150
cubic foot shielding gas cylinder, welding cables and
accessories. Includes stable platforms for welder and
gas bottle platform, lower tray for added storage
capacity and adjustable height handle.
For mounting welding machines to K520 carts that do not have slotted mounting holes,
Drill 9/32” holes (3 places) into the cart top as shown and attach the welding machine to the cart
with the proper hardware shown.
1/4"-20 X 1/2" Hex Head Cap Screw
(2 Required)
1/4"-20 X 1"
Thread Forming Screw
(1 Required)
1/4"-20 X 1/2" Hex Head Cap Screw
(2 Required)
3-3/4" (95.3mm)
9/32"(7.1mm) DRILL
3 PLACES
8-1/16" (204.8mm)
(96.8mm)
3-13/32"
3-11/16"
(93.7mm)
4"(102mm)
16"(406.4mm)
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C-4
C-4
ACCESSORIES
K2275-1 - Welding Cart
Lightweight cart stores and transports welder, 80 cubic
foot shielding gas cylinder, welding cables and acces-
sories. Includes an angled top shelf for easy access to
controls, lower tray for added storage capacity, a stur-
dy fixed handle and convenient cable wrap hanger.
For mounting welding machines to K2275 carts that do not have slotted mounting holes,
Drill 9/32” holes (3 places) into the cart top as shown and attach the welding machine to the cart
with the proper hardware shown.
1/4"-20 X 1/2" Hex Head Cap Screw
(2 Required)
1/4"-20 X 1"
Thread Forming Screw
(1 Required)
1/4"-20 Flange Nut
(2 Required)
9/32"(7.1mm) DRILL
3 PLACES
1-1/4"(31.8mm)
7-9/16"(192.1mm)
3-3/16"(81mm)
2-15/16"(74.6mm)
1-1/2"(38.1mm)
13-1/2"(342.9mm)
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C-5
C-5
ACCESSORIES
TECHNICAL SPECIFICATIONS - MAGNUM 100SG SPOOL GUN K2532-1
MODEL
K2532-1 Magnum 100SG Spool Gun
WELDING PROCESS
Aluminum GMAW (MIG), DC electrode positive polarity with
100% argon welding shielding gas.
WIRE ALLOYS
Aluminum only: alloys 4043 or 5356
WIRE SIZES (DIAMETERS)
SPOOL SIZE
Solid wire 0.030 or 0.035 inches (0.8 or 0.9 mm)
1 lb. weight, nominal 4 inch diameter spool
130 amps at 30% for 10-minute basis
RATED WELDING CURRENT
AND DUTY CYCLE
OVERALL WEIGHT
CABLE LENGTH
3.5 lbs. with cable but without case or spool
10.0±0.2 feet
OVERALL SIZE (BOUNDING BOX) In inches: 15.75 long x 10.50 high x 4.25 thick max.,
without case or gun cable.
METHOD OF GUIDANCE
METHOD OF COOLING
Semiautomatic (manually-guided)
Air-cooled
UNPACKING THE SPOOL GUN
The spool gun is factory-assembled and tested, and
then packed in its own cushioned carrying case. It is
shipped fully-equipped to weld with 0.035 inch diame-
ter aluminum wire. After opening the case, check that
it contains the following items:
1
2
1. One fully assembled K2532-1 spool gun with (1)
T11862-65 Conical Compression Spring for use
with alloy 5356 wire; wire spool not installed.
2. One spool of 0.035 aluminum alloy 4043 wire
3. Three S19726-3 contact tips
4. One instruction manual (IM913)
3
4
5. One M21182 electrical harness with toggle switch.
5
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C-6
C-6
ACCESSORIES
SAFETY PRECAUTIONS
WARNING
ELECTRICꢀSHOCK CAN KILL.
• Turn the input power OFF at the
welding power source before instal-
lation or changing drive rolls and/or
guides.
• Do not touch electrically live parts.
FIGURE C.1
• 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.
6
5
3
------------------------------------------------------------------------
LOCATING SPOOL GUN COMPONENTS
AND FEATURES
(See Figure C.1 for Items 1 thru 6)
1. Gas Cone Assembly and Contact Tip.
2. Straightened Gun Tube Assembly.
3. 1/4-Turn Locking Collar.
4. Trigger Assembly.
4
2
1
Left Side View
5. Spool Cover: Provides easy, wide-open access to
spool and wire drive.
6. Locking Knob: Captive in spool cover.
(See Figure C.2 for these following items)
FIGURE C.2
7. Integrated Single-Piece Cable: The Magnum design
provides neat and clean appearance; simplifies
cable management and reduces entanglements.
8. Standard Durable Strain Relief Clamp.
9. Three Captive Hex Nuts.
7
8
9
Right Side View
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C-7
C-7
ACCESSORIES
ASSEMBLY OF ITEMS INSIDE THE MAGNUM SPOOL GUN
FIGURE C.3
7
4
TOP VIEW
2
3
1
8
9
5
Spool Cover and left
handle removed
MASTER KEY
1
3
2
4
P6 CONNECTOR PINOUT
Machine Connections
6
1. Liner Assembly feeds all specified wire.
9. Only 4 sub-assemblies: gun tube; cable; wire drive;
trigger.
2. Drive Roll: This Drive Roll feeds all specified wires.
10. Conical spring (not shown) serves as the spool
brake (use only with aluminum alloy 5356).
3. Idle Roll Assembly: Non-adjustable tension setting
for all specified wires
4. Incoming Wire Guide: Highly wear-resistant.
5. P6 Connector Control Leads: Motor Power and
Trigger. (See Maintenance Section for more
details)
6. Welding Power and Shielding Gas Machine connec-
tion (Sealed with 2 o-rings).
7. Locking Knob: Independently retains the wire spool
on the spindle.
8. Liner Assembly: Includes a gas seal with the cable
connector and is the outgoing wire guide.
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C-8
C-8
ACCESSORIES
SAFETY PRECAUTIONS
WELDING MACHINES
CAUTION
• 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, hearing protection, welding
helmet, welding gloves, and weld-
ing leathers.
------------------------------------------------------------------------
SPOOL GUN
WARNING
ELECTRICꢀSHOCK CAN KILL.
• The spool of wire may fall out of
the gun if the locking knob is not
installed.
• Metal parts may be at welding
voltage (electrically "hot").
• Metal parts remain at welding voltage for sever-
al seconds after trigger is released. Read warn-
ing label on gun.
• This product shall not be used in precipitation,
or in wet or damp locations.
-------------------------------------------------------------------
RECOMMENDED WELDING MACHINES
The MAGNUM 100XL Spool Gun can be installed in all
machines covered by this Manual.
Machines that are not equiped with a gas solenoid from the
factory must have the K2526-1 MIG Conversion Kit added
before installing the MAGNUM 100XL Spool Gun.
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C-9
C-9
ACCESSORIES
SPOOL GUN / WIRE DRIVE
SELECTOR SWITCH INSTALLATION
1. Install the M21182 electrical adapter harness that
came with the spool gun per the following instruc-
tions.
A
WARNING
ELECTRICꢀSHOCK CAN KILL.
2. Disconnect input power from the machine.
------------------------------------------------------------------------
5. Remove screws from cover.
(A) is the location of two 3/4” long screws.
OPEN THE MACHINE
3. Remove two 5/16“ hex hinge screws from door.
6. Remove cover.
A
B
4. Remove ten 5/16“ hex screws from cover.
7. If machine has a plastic handle (A), then remove
screw (B).
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C-10
C-10
ACCESSORIES
ELECTRICAL CONNECTIONS
544A
(Male)
543A
P7
(Female)
Toggle Switch
J7 (10-pin)
J8 (6-pin)
P7 (10-pin)
J3
10. Connect harness P7 (10-pin) to board J3 (10-
pin).
P8 (6-pin)
IF MACHINE DOES NOT HAVE OPTIONAL SPOT TIMER.
(11.A. thru 11.D.)
8. Adapter harness. All 6 connections shown are
used, and each one is unique. (Proceed as follows)
P3
J3
P5
J5
11.A. Remove P5 (6-pin) from board J5 (6-pin).
9.A. Remove P3 (10-pin) from board J3 (10-pin).
P3
J7
J8
P5
11.B. Connect P5 (6-pin) to harness J8 (6-pin).
9.B. Connect P3 (10-pin) to harness J7 (10-pin).
P8
J5
11.C. Connect harness P8 (6-pin) to board J5 (6-
pin).
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C-11
C-11
ACCESSORIES
P8
544A
543A
J9
12.C. Connect adapter harness P8 (6-pin) to spot
timer harness J9 (6-pin).
11.D. Find assembled pair of machine terminals
(leads 543A & 544A) and disconnect. Go to
step 13.
IF MACHINE DOES HAVE OPTIONAL SPOT TIMER.
(12.A. thru 12.D.)
544A
543A
J9
P5
12.D. Find assembled pair of machine terminals
(leads 543A & 544A) and disconnect.
12.A. Remove P5 (6-pin) from spot timer harness J9
(6-pin).
B
A
J8
P5
12.B. Connect P5 (6-pin) to adapter harness J8 (6-
pin).
13. Connect terminals:
(A) connect machine male (lead 543A) to adapter
harness female (lead 543A).
(B) connect machine female (lead 544A) to
adapter harness male (lead 544A).
14. Ensure that the locking tabs on all connectors
are latched closed.
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C-12
C-12
ACCESSORIES
MOUNTING THE SWITCH
is fully seated into smaller hole.
19. Reinstall mounting nut onto switch.
15. Remove the plug button from the panel hole.
Wrench tighten.
RE-ASSEMBLE MACHINE AS FOLLOWS:
16. Plug button is no longer needed. Discard.
20. Reinstall screw into plastic handle (if so
equipped).
21. Reinstall cover.
22. Reinstall door.
23. Reconnect input power to the machine
17, Remove mounting nut from switch. Keep mount-
ing nut for installation.
18. Install switch into panel hole. Ensure washer tab
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C-13
C-13
ACCESSORIES
ROUTINE WELDING MACHINE
PREPARATION
WARNING
ELECTRICꢀSHOCK 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 and flow rate: Connect 100% welding
grade argon gas supply to the machine’s gas sole-
noid valve. Set the supply regulator to deliver a gas
flow rate of 20 to 50 SCFH thru the spool gun.]
4. Flip the machine’s wire drive selector switch (behind
the access door) to "Magnum 100SG". (See Figure
C.4)
FIGURE C.4
PREPARING THE SPOOL GUN
WARNING
ELECTRICꢀSHOCK CAN KILL.
1. Disconnect input power to the machine.
------------------------------------------------------------------------
2. The Conical Spring is used as the spool brake only
when feeding the stronger and harder aluminum
alloy 5356. The Conical Spring must be removed
from the spool gun whenever using the softer alu-
minum alloy 4043.
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C-14
C-14
ACCESSORIES
4. Extend approximately 12 inches of wire from spool.
Straighten it out by back-bending it. Use care to
prevent the wire from dereeling.
LOADING ALUMINUM WIRE
1. Remove gas cone and contact tip. Remove spool
cover by unscrewing captive locking knob.
FIGURE C.8
FIGURE C.5
5. Cut off bent end of wire, leaving straight section.
FIGURE C.9
2. Remove locking knob from spindle bolt by unscrew-
ing it.
FIGURE C.6
3. Select wire alloy and diameter needed. Alloy 4043
and 0.035 wire size shown. Remove packaging and
data sheet from wire spool.
6. Gently pull open the idle roll assembly to expose the
drive roll groove.
FIGURE C.10
FIGURE C.7
Size
Alloy
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C-15
C-15
ACCESSORIES
7. Guide straightened wire through inlet wire guide
and toward drive roll groove.
10a. Alloy 4043: Roll up remaining wire back onto
spool and place spool onto gun spindle. Install
locking knob and finger-tighten. Go to step 11.
FIGURE C.11
FIGURE C.14
10b. Alloy 5356: Install Conical Spring, small end first,
onto gun spindle (A). Roll up remaining wire back
onto spool and place spool onto gun spindle.
Install locking knob and finger-tighten.
Go to step 11.
8. While holding open the idle roll, slide end of wire
through drive roll’s groove and toward gun tube liner.
FIGURE C.12
FIGURE C.15
A
11. Grasp the free end of the wire at the gas diffuser
and slowly pull approximately 12 to 24 inches of
wire through the spool gun. There should only be 1
to 2 lbs. of resistance. If force is greater than 2 lbs.
wire is binding in the gun (also see Troubleshooting
guide).
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.13
FIGURE C.16
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C-16
C-16
ACCESSORIES
12. Cut off excess wire 1 to 2 inches from gas diffuser.
Install properly-sized contact tip slightly past hand-
tight. Install gas cone and hand-tighten.
CONNECTING THE GUN TO THE
WELDING MACHINE
1. Disconnect input power to the machine.
FIGURE C.17
2. Make sure that the gun locking knob is loosened.
(See Figure C.20).
3. Fully insert gun cable connection (welding power
and gas supply) into machine. Note that the master
Key way for P6 connector is located at the arrow.
FIGURE C.19
P6
Connector
Key way
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: check for uniform
fit all around cover.
FIGURE C.18
4. Check that the cable connector’s end is flush with
insulator at A. Tighten gun locking knob (B) onto
cable connector.
FIGURE C.20
4
1
3
2
A
B
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D-1
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Changing Liner, Gun Handle Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
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D-2
D-2
MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
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 and trouble shooting work.
---------------------------------------------------------------------------------
ROUTINE MAINTENANCE
POWER SOURCE COMPARTMENT
No user serviceable parts inside! Do not attempt to perform
service in the power source (fixed) side of the COMPACT EIRE
WELDERS. Take the unit to an authorized Lincoln Service
Center if you experience problems.
TYPCALLY, No regular maintenance is required. In extremely
dusty locations, dirt may clog the air passages causing the
welder to run hot with premature tripping of thermal protection.
If so, blow dirt out of the welder with low pressure air at regular
intervals to eliminate excessive dirt and dust build-up on inter-
nal parts.
WIRE FEED COMPARTMENT
1. When necessary, vacuum accumulated dirt from gearbox
and wire feed section.
2. Occasionally inspect the wire guides and keep grooves
clean.
3. Motor and gearbox have lifetime lubrication and require no
maintenance.
FAN MOTOR
Has lifetime lubrication — requires no maintenance.
WIRE REEL SPINDLE
Requires no maintenance. Do not lubricate shaft.
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D-3
D-3
MAINTENANCE
GUN AND CABLE
MAINTENANCE
5. To remove gun tube from gun, remove gas nozzle
or gasless nozzle and remove diffuser from gun
tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Loosen the locking nut holding the gun tube in
place against the gun end cable connector.
Unscrew gun tube from cable connector. To install
gun tube, screw the locking nut on the gun tube as
far as possible. Then screw the gun tube into the
cable connector until it bottoms. Then unscrew (no
more than one turn) the gun tube until its axis is
perpendicular to the flat sides of the cable connec-
tor and pointed in the direction of the trigger.
Tighten the locking nut so as to maintain the prop-
er relationship between the gun tube and the cable
connector. Replace the gun handle, trigger and dif-
fuser. Replace the gas nozzle or gasless nozzle.
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 pressure air, gently blow out the
cable liner from the gas diffuser end.
CAUTION
Excessive pressure at the start may cause the dirt
to form a plug.
OVERLOAD PROTECTION
Flex the cable over its entire length and again blow out
the cable. Repeat this procedure until no further dirt
comes out.
Output Overload
The Compact Wire Welders are equipped with a circuit
breaker and a thermostat which protects the machine
from damage if maximum output is exceeded. The cir-
cuit breaker button will extend out when tripped. The
circuit breaker must be manually reset.
Contact Tips, Nozzles, and Gun Tubes
1. Dirt can accumulate in the contact tip hole and
restrict wire feeding. After each spool of wire is
used, remove the contact tip and clean it by push-
ing a short piece of wire through the tip repeatedly.
Use the wire as a reamer to remove dirt that may be
adhering to the wall of the hole through the tip.
Thermal Protection
The Compact Wire Welders have a rated output duty
cycle as defined in the Technical Specification pages.
If the duty cycle is exceeded, a thermal protector will
shut off the output until the machine cools to a rea-
sonable operating temperature. This is an automatic
function of the machine and does not require user
intervention. The fan continues to run during cooling.
2. Replace worn contact tips as required. A variable or
“hunting” arc is a typical symptom of a worn contact
tip. To install a new tip, choose the correct size con-
tact 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.
Electronic Wire Drive Motor Protection
The Compact Wire Welders have built-in protection
against wire drive motor overload. If the motor current
limit is exceded the trigger circuit is interupted and the
weld stops.
3. Remove spatter from inside of gas nozzle and from
tip after each 10 minutes of arc time or as required.
4. Be sure the gas nozzle is fully screwed onto the dif-
fuser for gas shielded processes. For the
®
Innershield process, the gasless nozzle should
screw onto the diffuser.
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D-4
D-4
MAINTENANCE
1-1/4”(31.8 mm)
Liner Trim Length
Gas Diffuser
Gas Nozzle or
Gasless Nozzle
Set Screw
Brass Cable
Connector
Liner Assembly
(Liner bushing to be sealed tight
against brass cable connector)
FIGURE D.2
Liner trim length
8. Screw the gas diffuser onto the end of the gun tube
and securely tighten.
CHANGING LINER
9. Replace the contact tip and nozzle.
NOTICE: The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been cut
for a particular gun, it should not be installed in anoth-
er gun unless it can meet the liner cutoff length require-
ment. Refer to Figure D.2.
GUN HANDLE PARTS
The gun handle consists of two halves that are held
together with a collar on each end. To 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, 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. See Figure D-3.
1. Remove the gas nozzle from the gun by unscrewing
counter-clockwise.
2. Remove the existing contact tip from the gun by
unscrewing counter-clockwise.
3. Remove the gas diffuser from the gun tube by
unscrewing counter-clockwise.
4. Lay the gun and cable out straight on a flat surface.
Loosen the set screw located in the brass connector
at the wire feeder end of the cable. Pull the liner out
of the cable.
5. Insert a new untrimmed liner into the connector end
of the cable. Be sure the liner bushing is stenciled
appropriately for the wire size being used.
Counter-clockwise
6. Fully seat the liner bushing into the connector.
Tighten the set screw on the brass cable connector.
At this time, the gas diffuser should not be installed
onto the end of the gun tube.
7. With the gas nozzle and diffuser removed from the
gun tube, be sure the cable is straight, and then trim
the liner to the length shown in the Figure D.2.
Remove any burrs from the end of the liner.
FIGURE D.3
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D-6
D-6
MAINTENANCE
MAJOR COMPONENT LOCATIONS
1. Case Front Assembly
2. Wire Drive Assembly
3. Center Panel Assembly
4. Power Module and Base Assembly
5. Wraparound & Door Assembly
5
4
3
1
2
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Thermal Protection, Output Overload & Electronic Wire Drive Motor Protection . . . . . . . . . . . . . . . . . . . .E-7
FIGURE E.1 — BLOCK LOGIC DIAGRAM.
ARC
VOLTAGE
CONTROL
WIRE
SPEED
CONTROL
TRIGGER
RECEPTACLE
CONTROL
BOARD
GAS
SOLENOID
LINE
SWITCH
CIRCUIT
BREAKER
INPUT
RECEPTACLE
FAN
MOTOR
WIRE
FEED
MOTOR
VOLTAGE FEEDBACK &
MOTOR POWER
+
+
CHOKE
OUTPUT
TERMINALS
MAIN
TRANSFORMER
MAIN
BRIDGE
-
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 — GENERAL DESCRIPTION
ARC
VOLTAGE
CONTROL
WIRE
SPEED
CONTROL
TRIGGER
RECEPTACLE
CONTROL
BOARD
GAS
SOLENOID
CIRCUIT
LINE
BREAKER SWITCH
INPUT
RECEPTACLE
FAN
MOTOR
WIRE
FEED
MOTOR
VOLTAGE FEEDBACK &
MOTOR POWER
+
+
CHOKE
OUTPUT
TERMINALS
MAIN
TRANSFORMER
MAIN
BRIDGE
-
GENERAL DESCRIPTION
The Compact Wire Welders that are covered by this
manual are Constant Voltageꢀ(CV) DC welders that
can be used for MIG or Flux-Core process . The 120
VAC machines are rated for 90 amps, 19.5 volts, at
20% duty cycle. The 208 / 230 VAC machines are
rated for 130 amps, 17 / 20 volts, at a 30% duty
cycle. All are equipped with a 4-pin trigger connec-
tor to allow operation of an optional spool gun for
Aluminum MIG Welding.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 — INPUT POWER CIRCUITS
ARC
VOLTAGE
CONTROL
WIRE
SPEED
CONTROL
TRIGGER
RECEPTACLE
CONTROL
BOARD
GAS
SOLENOID
CIRCUIT
LINE
BREAKER SWITCH
INPUT
RECEPTACLE
FAN
MOTOR
WIRE
FEED
MOTOR
VOLTAGE FEEDBACK &
MOTOR POWER
+
+
CHOKE
OUTPUT
TERMINALS
MAIN
TRANSFORMER
MAIN
BRIDGE
-
INPUT LINE VOLTAGE, FAN 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 and high
current output suitable for welding.
The fan motor is rated for the same AC Voltage as the
welder and should run whenever the machine is Power
Switch is turned ON.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 — OUTPUT CIRCUITS
ARC
VOLTAGE
CONTROL
WIRE
SPEED
CONTROL
TRIGGER
RECEPTACLE
CONTROL
BOARD
GAS
SOLENOID
CIRCUIT
LINE
BREAKER SWITCH
INPUT
RECEPTACLE
FAN
MOTOR
WIRE
FEED
MOTOR
VOLTAGE FEEDBACK &
MOTOR POWER
+
+
CHOKE
OUTPUT
TERMINALS
MAIN
TRANSFORMER
MAIN
BRIDGE
-
OUTPUT CONTROL,
RECTIFICATION & VOLTAGE
FEEDBACK
The board circuitry then sends a pulse to turn on the
SCRs. In this manner, the voltage applied to the pri-
mary of the transformer is varied and controlled. This
controlled voltage is reflected at the transformer sec-
ondary winding and is applied to the rectifier diode
bridge. This rectified DC voltage is filtered by the out-
put capacitor and choke circuit and is applied to the
machine’s output terminals.
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 compares the commands of the arc volt-
age control with the voltage feedback signal. (The Arc
Voltage Control may be either a continuous control or
a selector switch, depending on the model of the
machine).
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 — TRIGGER, GAS SOLENOID & WIRE DRIVE
ARC
VOLTAGE
CONTROL
WIRE
SPEED
CONTROL
TRIGGER
RECEPTACLE
CONTROL
BOARD
GAS
SOLENOID
CIRCUIT
LINE
BREAKER SWITCH
INPUT
RECEPTACLE
FAN
MOTOR
WIRE
FEED
MOTOR
VOLTAGE FEEDBACK &
MOTOR POWER
+
+
CHOKE
OUTPUT
TERMINALS
MAIN
TRANSFORMER
MAIN
BRIDGE
-
TRIGGER, GAS SOLENOID AND
WIRE DRIVE
The voltage that powers the wire drive motor is varied
and controlled on the control board in response to the
setting of the Wire Speed Control. The control board
monitors the drive motor armature current and voltage
and compares the feedback information with the com-
mands sent from the wire speed control to maintain a
constant wire speed.
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 main transformer.
The output voltage that is developed at the output ter-
minals is also fed back to the control board to facilitate
control of the output and also to power the Wire feed
Motor circuitry.
The Control Board also has an automatic protection
circuit, which shuts off the trigger circuit in the event of
a wire drive motor overload.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-6
E-6
THEORY OF OPERATION
SCR OPERATION
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 turned OFF, there is no current flow from anode
to cathode, thus the device acts like an open switch.
As the name suggests, the SCR is a rectifier, so it
passes current only during positive half cycles of the
AC supply. The positive half cycle is the portion of the
sine wave in which the anode of the SCR is more pos-
itive than the cathode.
An SCR is fired by a short burst of current into the gate.
This gate pulse must be more positive than the cath-
ode voltage. Since there is a standard PN junction
between gate and cathode, the voltage between these
terminals must be slightly greater than 0.6V. Once the
SCR has fired, it is not necessary to continue the flow
of the gate current. As long as current continues to
flow from anode to cathode, the SCR will remain on.
When the anode to cathode current drops below a min-
imum value, called holding current, the SCR will shut
off. This normally occurs as the AC voltage passes
through zero into the negative portion of the sine wave.
If the SCR is turned on early in the positive half cycle,
the conduction time is longer, resulting in greater SCR
output. If the gate firing occurs later in the cycle, the
conduction time is less, resulting in lower SCR output.
When an AC supply voltage is applied to the SCR, the
device spends a certain portion of the AC cycle time in
the ONꢀstate, and a remainder of the time in the OFF
state. The gate controls the amount of time spent in
each state.
FIGURE E.6 — SCR OPERATION
INPUT
CATHODE
OUTPUT
GATE
NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
ANODE
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E-7
E-7
THEORY OF OPERATION
THERMAL PROTECTION
The Compact Wire Welders have a rated output duty
cycle as defined in the Technical 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
and does not require user intervention. The fan contin-
ues to run during cooling. If the fan is not turning or the
air intake louvers become obstructed, the input power
must then be removed and the fan problem or air
obstruction corrected.
OUTPUT OVERLOAD
The Compact Wire Welders are equipped with a circuit
breaker which protects the machine from damage if
maximum output is exceeded. The circuit breaker must
be manually reset.
ELECTRONIC WIRE DRIVE MOTOR PROTECTION
The Compact Wire Welders built-in protection for wire
drive motor overload.
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E-8
E-8
NOTES
COMPACT WIRE WELDERS
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F-1
F-1
TABLE OF CONTENTS - TROUBLESHOOTING & 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
Case Cover Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11
Gas Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Wire Drive Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Main Transformer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17
Fan Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-21
Typical Output Voltage Waveform - Machine Loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Control Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Power Module Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Rectifier, Transformer, Choke Assembly & Capacitor Removal and Replacement . . . . . . . . . . . . . . . . . .F-33
Wire Drive Motor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39
Fan Motor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43
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F-2
F-2
TROUBLESHOOTING & 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.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
Course of Action” lists the most likely com-
procedure listed below.
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com-
ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob-
lems, wire feeding problems, and welding
problems.
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.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
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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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- 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-shield-
ing bag.
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.
- 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 prop-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
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:
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
- Remove your body’s static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
equipment frame.
grounded part of the
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
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.
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical
damage is evident.
1. Contact the Lincoln Electric
Service Dept.
1-888-935-3877.
1. Contact your local Lincoln
Authorized Field Service
Facility.
1. Check input power switch
(S1) it may be faulty. See
Wiring Diagram.
1. Make sure correct voltage is
applied to the machine.
Machine is dead - no open
circuit voltage, wire feed, gas
flow when trigger is pulled and
fan does not operate.
2. Make certain that the power
switch is in the “on” position.
2. Check lead connection and
correct function of circuit
breaker. See Wiring
3. Blown fuses in the input line.
Check circuit breaker on the
machine.
3. The Control P.C. Board may
be faulty
No weld output, wire feed, gas
flow when the trigger is pulled.
Fan does run.
1. The thermostat may be open
due to machine overheating. If
machine operates normal after
a cooling off period then check
for proper fan ventilation,
1. Check thermostat and
associated leads for loose or
broken connections. See
wiring diagram.
2. Remove main power supply to
the machine. With the gun
trigger pulled check for
remove any obstructions. Make
certain that the machine’s duty
cycle is not being exceeded.
continuity at pins 6 and 3 on
plug J5 on the control board.
2. Gun trigger may be faulty.
4. Check all heavy current
carrying leads. Check for loose
or broken connections at the
transformer, choke and
rectifier.
5. Make sure identity plug is not
missing on control board. See
6. Possible bad control board.
Replace.
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.
COMPACT WIRE WELDERS
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F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT/FEEDING PROBLEMS
The machine has output, wire
feed, gas flow but NO fan.
1. Possible faulty fan motor.
2. Check for continuity between
#6 to Fan or #1 to Fan on
Control P.C. Board. Replace.
2. Possible faulty Control P.C.
Board.
1. Possible bad drive motor.
The machine has output, gas
flow and fan but does not have
wire drive.
2. If 3 - 30 vdc is not at the drive
motor check for OCV at the
board on pins 1 and 10 on J3.
If OCV is present possible
faulty Control P.C Board.
Replace. If OCV is not
2. Possible bad Control P.C.
Board.
present check continuity of
wires CAP- and CAP+.
No wire feed when gun trigger is
pulled. Fan runs, gas flows and
machine has correct open circuit
voltage. ( 33 vdc maximum) -
weld output.
1. If the wire drive motor is
running, make sure that the
correct drive roll and wire
guide is installed in the
machine.
2. If wire drive test is OK, then
check for OCV at CAP- and
CAP+ on the control board. If
correct voltage is present,
possible faulty Control P.C.
Board. Replace.
2. Check for clogged cable liner
or contact tip.
3. Check for proper size cable
liner and contact tip.
3. If open circuit voltage is not
present at CAP- and CAP+ on
control board check continuity
of leads.
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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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
The machine stops feeding wire
with trigger pulled. Re-trigger
and machine starts feeding wire
again.
1. Check the motor armature
current. If high (over 2.5
amps) and there are no
1. Check for adequate wire
supply.
2. Check for mechanical
restrictions in the wire feeding
path. The gun may be clogged.
restrictions in the wire feeding
path, then the motor or gear
box may be faulty. Replace.
3. Make sure the gun liner and
tip are correct for the wire size
being used.
2. If motor armature current is
below 2.5 amps. The Control
P.C. board may be faulty.
Replace.
4. Check spindle for ease of
rotation.
1. Remove main supply power to
the machine. Disconnect plug
J3 from the control board.
Test the resistance from lead
MOT- in the harness plug to
the wire feed motor case. If
resistance is below 500,000
ohms, replace the drive
motor.
1. Possible faulty drive motor.
2. Possible faulty Control board.
1. Wire drive speed stays on one
speed. No wire speed control.
2. If no voltage charge is seen
on MOT+ and MOT- when
turning wire speed
potentiometer, the Control
P.C. Board may be faulty.
Replace.
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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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
The arc is unstable - poor
starting.
1. Check for 17 to 33 VDC
(dependent on Arc Voltage
Control Setting) at the
1. Check for correct input voltage
to the machine.
2. Check for proper electrode
polarity for process.
machine’s output terminals. If
present check gun and work
cable.
3. Check gun tip for wear or
damage-Replace.
2. If OCV is low, check output
capacitor and output diodes.
4. Check for proper gas and flow
rate for process.
3. Check for loose connections
at the output terminals, the
choke and all heavy current
carrying leads. See Wiring
5. Check work cable for loose or
faulty connections.
6. Check gun for damage or
breaks
4. The Control P.C. Board may
be faulty. Replace.
GAS FLOW PROBLEMS
1. Check the gas solenoid by
disconnecting it from the
control board and applying a
12 vdc external supply to the
gas solenoid. If solenoid does
not activate it may be faulty.
Replace.
1. Check gas supply, flow
regulator and gas hoses.
Low or no gas flow when gun
trigger is pulled. Wire feed, weld
output and fan operate normally.
2. Check gun connection to
machine for obstruction or
leaky seals.
2. The control P.C. board may
be faulty. Replace.
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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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
SPOOL GUN PROBLEMS
No wire feed occurs when Spool
Gun trigger is pulled.
1. Switch on or plug in machine.
1. Machine is switched off or
unplugged.
2. Install full spool of specified
wire.
2. Spool gun is out of wire
3. Contact tip burnback.
3. Replace contact tip.
4. Replace and clean or replace
gun tube liner. ( See
4. Fully or partially blocked gun
tube liner.
5. Bird nest.
5. Cut out birds nest, reload
wire, and check for proper
wire alignment and wire’s
mechanical resistance.
6. Machine’s toggle selector
switch is not set to spool gun
mode.
7. Defective trigger. (contacts
open)
6. Flip switch to proper
operating position.
8. Defective trigger circuit in gun.
9. Damaged spool gun motor.
7. Replace trigger. ( See
8. Disconnect gun from machine
and check trigger for
continuity.
10. No motor voltage or current
from machine.
11. Contact tip size too small for
wire diameter used.
9. Contact LASF for possible
motor replacement.
10. See Troubleshooting section
in welding machine’s
instruction manual.
11. Replace contact tip with one
that is the right size.
1. Clean drive roll of all
aluminum or replace drive
roll.
1. Drive roll is worn or galled with
aluminum.
Sluggish wire feed when the
Spool Gun trigger is pulled.
2. Machine’s wire feed speed
setting is too low.
2. Increase wire feed speed.
3. Check for obstructions:
remove any wire shavings;
remove kinked wire; remove
and clean or replace gun tube
liner ( See Maintenance
3. Wire is obstructed somewhere
along the wire feed path in the
gun.
4. Low motor voltage.
4. See Troubleshooting section
in welding machine’s
instruction manual.
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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F-9
Observe Safety Guidelines detailed in the beginning of this manual.
F-9
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
SPOOL GUN PROBLEMS
Intermittent wire feed when the
Spool Gun trigger is pulled.
1. Check that wire is properly
aligned inside gun.
1. Wire is mechanically binding
along its feed path inside gun.
2. Check that drive roll is
2. Drive roll has become loose on
hub and output shaft.
securely fastened in place by
SHCS (socket head cap
screw); replace hub and twist-
lock if worn.
3. Drive roll has become galled
with aluminum.
4. Wire has become kinked along
its feed path.
3. Remove and then clean or
replace drive roll. (See
5. Liner assembly is shaving
wire.
4. Manually pull wire slowly thru
gun until unkinked wire
emerges.
5. Check that wire is properly
aligned at liner inlet; realign
gun tube with wire drive. (See
Correcting Wire Shaving
proper Welding information.
1. Improper welding parameters
or technique. ( Example:
CTWD (Contact Tip to Work
Distance) is incorrect.
Frequent occurrences of contact
tip burnback when using the
Spool Gun.
2. See symptoms on intermittent
or sluggish wire feed.
2. Wire may be feeding
intermittently.
Poor weld bead appearance
(porosity or dull grey oxidized
surface) When using the Spool
Gun.
1. No gas flow.
2. Low gas flow.
1. See symptom “Low or no gas
flow”
2. See symptom “Low or no gas
flow”
3. Improper or contaminated
shielding gas.
3. Check that the gas supply’s
labeling reads 100% argon.
Temporarily use alternate,
known gas supply and check
for appearance improvement.
4. Welding in a windy
environment.
5. Improper electrode polarity.
6. Improper welding parameters
or technique.
4. Erect a wind shield or move to
a non-windy location before
welding.
5. Reconnect machine’s welding
output to electrode positive
polarity.
information.
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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F-10
Observe Safety Guidelines detailed in the beginning of this manual.
F-10
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
SPOOL GUN PROBLEMS
Low or no shielding gas flow.
1. Check that an adequate gas
supply is available.
1. Out of gas.
2. Gas supply is turned off or
disconnected.
2. Check that all gas supply
valves are open.
3. Gas supply flow regulator is
improperly set.
3. Check that all gas flow is set
between 20 to 50 SCFH.
4. Machine’s gas solenoid valve
has malfunctioned.
4. See machine’s instruction
manual.
5. Blockage in gun along gas
path.
5. Gently blow out debris from
core tube.
6. Gun cable kinked or flattened.
6. Attempt to straighten out
cable, or replace cable. (See
7. Blockage due to excessive
spatter accumulation on gas
cone or gas diffuser.
7. Clean or replace gas cone or
gas diffuser.
8. Excessive gas leakage from
supply.
8. Find and repair all leaks.
9. Gas leakage in gun between
liner assembly and cable
connector.
9. Replace liner assembly. (See
10. Damaged o-rings: replace
both seals. Gun connector
not fully inserted into
machine. ( See Installation
10. Gas leakage at gun-to-feeder
connection.
1. Replace trigger. (See
1. Defective trigger. (contacts
closed).
Spool Gun runs or begins
feeding wire without pulling the
gun trigger.
2. See machine’s instruction
manual.
2. Defective (closed) trigger
circuit in the welding machine.
3. Damaged control leads
between machine’s P6
3. Trigger lead(s) inside gun
cable are shorted together or
commonly shorted to either
welding or motor circuits.
connector and cable; repair if
possible. Otherwise, replace
gun cable. (See Maintenance
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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F-11
F-11
TROUBLESHOOTING & REPAIR
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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 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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the case cover.
MATERIALS NEEDED
Misc. Hand Tools
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F-12
F-12
TROUBLESHOOTING & REPAIR
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.1 – CASE REMOVAL
2 Phillips Screws
on Models with
Metal Handle
3/4”
Screws
5/16 Hex Head Screws
(2 Places)
5/16 Hex Head
on Models with
Plastic Handle
LINCOLN
ELECTRIC
PROCEDURE
1. Disconnect power to the machine.
2. Remove the two(2) 5/16 hex-head screws from the
top of the door and remove the door
3. Remove the ten(10) hex-head screws from the top
and left side of the machine. Note the position of the
two(2) longer screws. See Figure F.1
NOTE: If the machine has a plastic handle, remove the
5/16 hex-head screw from the front and remove
the handle.
4. Carefully lift and remove case cover from the
machine.
NOTE: Depending on what needs to be done, it may
be desirable to remove the handle on machines
with the metal handle. See Figure F.1
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F-13
F-13
TROUBLESHOOTING & REPAIR
GAS SOLENOID TEST
WARNING
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 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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the gas solenoid is receiving the correct voltage and if the sole-
noid is functional.
MATERIALS NEEDED
Misc. Hand Tools
Volt-Ohmmeter
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F-14
F-14
TROUBLESHOOTING & REPAIR
GAS SOLENOID TEST (CONTINUED)
FIGURE F.2 – GAS SOLENOID LOCATION & LEADS
Gas Solenoid
Leads
PROCEDURE
6. If the 6.5 VDC is missing or is low, check the leads
and connections between the solenoid and the con-
1. Remove input power to the machine.
3. Locate the gas solenoid and lead connections. Do
not disconnect the leads. See Figure F.2.
7. If the leads and connections are good to the board,
verify the correct supply voltage 9 -33 VDC at pins
1 and 10 at P3 on the control board. See Wiring
WARNING
ELECTRIC SHOCK can kill.
8. If voltage is correct at P3, the control board may be
faulty. Replace the control board.
•
Have an electrician install and
9. If the 6.5 VDC is present at the solenoid leads and
the solenoid does not activate, the solenoid may be
faulty. Normal solenoid coil resistance is approxi-
mately 22 ohms.
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
10. The solenoid can be further checked by discon-
necting the solenoid leads and applying 12VDC
directly to the terminals. If the solenoid does not
activate, the solenoid is faulty.
4. Turn the machine on and pull the gun trigger to con-
duct the voltage test.
5. There should be approximately 6.5 VDC at the sole-
noid.
11. Replace all disconnected leads and replace the
previously removed case cover.
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F-15
F-15
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR TEST
WARNING
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 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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the wire drive motor circuit is functioning properly.
MATERIALS NEEDED
Misc. Hand Tools
Volt-Ohmmeter
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F-16
F-16
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR TEST (CONTINUED)
FIGURE F.3 – PLUG P3
MOT-
MOT+
TEST PROCEDURE
c) Turn the machine ON and pull the gun trigger to con-
duct the voltage test.
NOTE: POLARITY MUST BE OBSERVED FOR
THESE TESTS.
Test for correct wire drive motor armature voltage.
1. Disconnect main input power to the machine.
FROM LEAD
MOT+
TO LEAD
MOT-
1.5-12.5 VDC
Board.
4. Locate the MOT+ and MOT- armature leads on Plug
6. If the voltage to the wire drive motor armature is
zero, check the wires between plug P3 and the wire
drive motor.
5. Make the following voltage tests:
WARNING
7. If the leads and connections are good to the board,
verify the correct supply voltage 9-33 VDC at pins 1
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.
8. If voltage is correct at P3, the control board may be
faulty. Replace the control board.
a) Turn the machine off between each test.
b) Carefully insert the meter probes into the lead side
of plug P3. See Figure F.3
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F-17
F-17
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST
WARNING
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 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 trou-
bleshooting 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 windings of the main transformer.
MATERIALS NEEDED
Misc. Hand Tools
Volt-ohmmeter
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F-18
F-18
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST (CONTINUED)
1. Remove the input power to the machine.
Secondary Test Procedure
Note: Secondary voltages will vary proportionately
with primary input voltage. For this test, place
voltage control potentiometer to maximum.
3. Locate H1 and H2 on the control board terminal
4. Place the voltage control to maximum.
5. Turn machine on and close trigger switch.
WARNING
ELECTRIC SHOCK can kill.
2. Isolate the two secondary leads located in the
Rectifier. Turn the machine on and close the gun
trigger.
•
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.
3. On 120 Volt Machines we should see 21 VAC at X1
and X2.
4. On 230 Volt machines we should see 25 VAC at X
and X2.
Turn the machine OFF between each test.
------------------------------------------------------------------------
5. If any of the voltages are incorrect or missing, check
for loose or broken connections. Possible bad
transformer.
6. On 120 Volt machines you should see 120 VAC or
input voltage at H1 and H2 on the terminal strips.
7. On 230 Volt machines you should see 230 VAC or
input voltage at H1 and H2 on the terminal strips.
8. If the correct input voltage is not at H1 and H2,
check for correct input voltage at 1 and 6 and not at
H1 and H2, possible bad Control Board.
9. If the correct voltage is being applied at 1 adn 6 and
not at H1 and H2, possible bad Control Board.
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F-20
F-20
NOTES
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F-21
F-21
TROUBLESHOOTING & REPAIR
FAN MOTOR TEST
WARNING
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 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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the fan motor is receiving the correct voltage
MATERIALS NEEDED
Misc. Hand Tools
Volt-Ohmmeter
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F-22
F-22
TROUBLESHOOTING & REPAIR
FAN MOTOR TEST (CONTINUED)
1. Remove the input power to the machine.
7. If the correct voltages are not there, check for cor-
rect input voltages at terminal strip 1 and 2 on ter-
F.5.
3. Locate the fan terminals on the Control board on
terminal strip 1 and terminal strip 2. See Wiring
8. If correct voltages are at terminals 1 and 6 and not
at FAN terminals, possible faulty Control Board.
4. Turn machine on to conduct voltage test.
9. If the correct voltages are at the FAN terminals, then
check for correct voltages at the fan motor. See
WARNING
ELECTRIC SHOCK can kill.
•
Have an electrician install and
10. If the correct voltages are at the fan motor, possi-
ble bad motor.
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
11. the correct voltages are at the fan motor, check for
bad or broken leads or terminals.
Turn the machine OFF between each test.
------------------------------------------------------------------------
5. On 120 Volt Machines, at the FAN terminals on ter-
minal strip 1 and 2, there should be 120 VAC. See
6. On 230 volt machines, at the FAN terminals on ter-
minal strip 1 and 2, there should be 230 VAC. See
FIGURE F.5. – CONTROL BOARD LEAD LOCATION(S)
Terminal Strip 2
Terminal Strip 1
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F-23
F-23
TROUBLESHOOTING & REPAIR
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
C1
0 volts
10Volts
20ms
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 SETTINGS
Volts/Div.....................10V/Div.
Horizontal Sweep...20 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-24
F-24
TROUBLESHOOTING & REPAIR
ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
C1
0 volts
10Volts
20ms
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 at the
machine output terminals. Positive
probe to (+) terminal, negative probe
to (-) terminal.
SCOPE SETTINGS
Volts/Div.....................10V/Div.
Horizontal Sweep...20 ms/Div.
Coupling.............................DC
Trigger.........................Internal
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F-25
F-25
TROUBLESHOOTING & REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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 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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Control
Board.
MATERIALS NEEDED
5/64" Allen Key
1/2” Nutdriver
Phillips Screwdriver
Flathead Screwdriver
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F-26
F-26
TROUBLESHOOTING & REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.6 – CONTROL BOARD LOCATION
Control
Board
1. Remove the input power to the machine.
6. Gently pull the case front forward about an inch to
gain access to the Control Board.
WARNING
7. Label and disconnect all plugs and leads connected
to the Control Board.
ELECTRIC SHOCK can kill.
•
Have an electrician install and
8. Remove and Replace the Control Board.
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
9. Connect all previously removed leads and plugs to
the new Control Board.
not touch electrically hot parts.
------------------------------------------------------------------------
10. Install all previously removed mounting hardware.
11. Install case wraparound cover.
3. Locate the Control Board. See Figure F.6.
4. Remove the two set screws from the voltage and
wire speed knobs using a 5/64” allen key. Remove
the two nuts and washers using a1/2” Nutdriver.
5. Remove the two phillips head screws from the
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F-28
F-28
NOTES
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F-29
F-29
TROUBLESHOOTING & REPAIR
POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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 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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Power
Module.
MATERIALS NEEDED
Misc. Hand Tools
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F-30
F-30
TROUBLESHOOTING & REPAIR
POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.8 – CASEBACK MOUNTING SCREWS
Phillips Handle Mount Screw
(only found on 140c/180c models)
2 Phillips
Screws
4 Phillips Screws
(only found on 140c/180c models)
VIEWED FROM REAR OF MACHINE
1. Disconnect main input power to the machine.
Note: On machines 140C & 180C, a total of four flat-
head screws must be removed from the case-
back prior to depressing locking tabs.
5. Label and remove the appropriate wiring and gas
hose from the top of the Power Module Chasis.
WARNING
ELECTRIC SHOCK can kill.
•
6. Remove the two flathead screws from the center
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
7. Note position and remove bolts on the Choke &
Rectifier.
not touch electrically hot parts.
------------------------------------------------------------------------
8. The Power Module may now be removed from the
machine as a single unit.
4. Remove the two flathead mounting screws on the
caseback and depress the two locking tabs to
remove. See Figure F.8.
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F-32
F-32
NOTES
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F-33
F-33
TROUBLESHOOTING & REPAIR
RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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 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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
WARNING
The liquid electrode in the capacitors is toxic. Do not touch the capacitors with any
part of your body.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the components
in the Power Module Assembly.
MATERIALS NEEDED
Misc. Hand Tools
Dow Corning 340
Fine Steel Wool
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F-34
F-34
TROUBLESHOOTING & REPAIR
RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.10 – LOCKING TABS
Locking Tabs
3/8”Bolted Lead
(opposite side not shown)
5. Using a 3/8” nutdriver, remove the two bolted leads
from the sides of the Rectifier. See Figure F.10.
1. Remove the input power to the machine.
6. Label and disconnect any associated leads.
7. Remove Rectifier and Capacitor from the machine.
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.
------------------------------------------------------------------------
4. With the Power Module removed from the machine,
depress locking tabs and remove the top chassis of
the module. See Figure F.10.
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F-35
F-35
TROUBLESHOOTING & REPAIR
RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.11 – DOW CORNING 340
Dow Corning 340
(Apply to area,opposite side not shown))
8. When re-installing the capacitor, make sure that the
9. Clean the terminal surface of the capacitor with fine
steel wool and apply a thin coating of Dow Corning
10. On the rectifier, clean the terminal surface with fine
steel wool and apply a thin coating of Dow Corning
340 on the Rectifier and re-install. See Figure F.11.
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F-36
F-36
TROUBLESHOOTING & REPAIR
RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR
REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.12 – DOW CORNING APPLICATION AREAS
Nut
LockW asher
Plain W asher
Locking Tab
Inserts
Dow Corning 340
(apply to contact surfaces on both term inals)
TRANSFORMER AND CHOKE
11. With the Power Module removed from the
machine, remove the top chassis on the
Module.
15. When re-installing the Transformer, clean the
terminal surface and apply Dow Corning 340 to
12. Remove the two bolted leads from the sides of
the rectifier using a 3/8” nutdriver.
Note: This step may already be complete.
13. Label and disconnect any additional necessary
leads.
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F-38
F-38
NOTES
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F-39
F-39
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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 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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Wire Drive
Motor.
MATERIALS NEEDED
Misc. Hand Tools
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F-40
F-40
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.14 – CASEFRONT KNOB REMOVAL
Nameplate
Control Knob
LINCOLN
ELECTRIC
5/64”Allen
Set Screw
Phillips
Screws
1. Remove the input power to the machine.
5. Remove the two phillips head screws from the
nameplate of the machine. See Figure F.14.
6. Gently pull the case front forward about an inch to
gain access.
WARNING
ELECTRIC SHOCK can kill.
7. Disconnect the air line from the wire drive motor.
Pliers may be necessary.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
8. Label and disconnect any necessary leads. The
number of leads may vary depending upon the
machine’s model number.
not touch electrically hot parts.
------------------------------------------------------------------------
3. Remove the two phillips screws from the gun trigger
receptacle.
9. Remove the three phillips mounting screws from the
4. Remove the two set screws from the voltage and
wire speed knobs using a 5/64” allen key. Remove
the two nuts and washers using a 1/2” Nutdriver.
See Figure F.14.
10. Remove the Wire Drive Motor and replace.
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F-42
F-42
NOTES
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F-43
F-43
TROUBLESHOOTING & REPAIR
FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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 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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Fan Motor
Assembly.
MATERIALS NEEDED
5/16” Nut Driver
5/64” Allen Key
1/2” Nut Driver
Phillips Screwdriver
Flathead Screwdriver
Pliers
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F-44
F-44
TROUBLESHOOTING & REPAIR
FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.16 – CENTER PANEL/FAN MOUNTING SCREW LOCATION
Phillips Handle Mount Screw
(only found on 140c/180c models)
2 Phillips
Screws
4 Phillips Screws
(only found on 140c/180c models)
VIEWED FROM REAR OF MACHINE
1. Remove the input power to the machine.
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.
------------------------------------------------------------------------
4. Using a flathead screwdriver, remove the center
panel mounting screws and the fan mounting
screws (depending upon model) located on the
back of the machine. See Figure F.16.
5. Depress any necessary locking tabs on rear of
machine.
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F-45
F-45
TROUBLESHOOTING & REPAIR
FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.17 – CENTER PANEL MOUNTING SCREWS
Center
Panel
Center Panel Screws
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. See Figure F.17.
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F-46
F-46
TROUBLESHOOTING & REPAIR
FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE
(CONTINUED)
FIGURE F.18 – LOCKING TABS & FAN
Locking Tabs
Fan
8. Depress the locking tabs and remove the top
Power Module Chassis. See Figure F.18.
11. Upon installation of the new fan motor, make
sure that the rotation arrow is pointing up and
the flow arrow is pointing toward the front of the
machine.
9. Label and disconnect any necessary leads
attached to the Fan.
Note: Fan should spin counter clockwise when
viewed from the rear of the machine.
10. Remove the fan from the machine.
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F-47
F-47
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR (125 AMP UNITS)
INPUT IDLE AMPS & WATTS
Input Volts/Hertz
120/60
Maximum Idle Amps
3.00
Maximum Idle Watts
200
OPEN CIRCUIT VOLTAGE
9-33 VDC
WIRE SPEED RANGE
50-500 in./min. (1.3-12.7 m/min)
RETEST AFTER REPAIR (140 AMP UNITS)
INPUT IDLE AMPS & WATTS
Input Volts/Hertz
120/60
Maximum Idle Amps
4.50
Maximum Idle Watts
325
OPEN CIRCUIT VOLTAGE
9-33 VDC
WIRE SPEED RANGE
50-500 in./min. (1.3-12.7 m/min)
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F-48
F-48
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR (180 AMP UNITS)
INPUT IDLE AMPS & WATTS
Input Volts/Hertz
230/60
Maximum Idle Amps
2.50
Maximum Idle Watts
275
OPEN CIRCUIT VOLTAGE
9-33 VDC
WIRE SPEED RANGE
50-500 in./min. (1.3-12.7 m/min)
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram - (M20410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram - Spool Gun Option - (M20410-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Wiring Diagram - Code 11444 - (M20410-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Wiring Diagram - Code 11442 - (M20410-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Machine Schematic - (M21240) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
Schematic – Machines with Voltage Switch - (G4741-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Schematic – Machines with Continuous Control - (G4822-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8
Schematic Filter PC Board Assembly - (S24206-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-
layered and are therefore considered to be unserviceable. Assembly drawings of these
boards are no longer provided.
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G-2
G-2
ElEcTrical DiaGramS
WiriNG DiaGram - cOmplETE machiNE - (m20410)
WIRING DIAGRAM
WARNING
N.G.
Do not operate with covers removed.
WORK
Disconnect input power by unplugging
power cord before servicing.
SPOOL GUN
(OPTIONAL)
Do not touch electrically live parts
Only qualified persons should install,
use or service this machine.
MOTOR
HIGH VOLTAGE
can kill
EITHER
GUN
WIRE FEED MOTOR
MOT+
MOT-
RIBBED OR
STRIPED LEAD
J6
P6
N.B.
2A
1
4A
543A
544A
5
6
S1
CB1
SMOOTH
LEAD
GND
TS2
N.E.
OUTPUT
CHOKE
6
FAN
H1
TO GROUND
PER NATIONAL
ELECTRICAL
CODE.
N.D.
IDENTITY PLUG
N.A.
N.A.
X1
H1
CAPACITOR
C1
SEE
X1
CONFIGURATION
DETAIL BELOW
D1
TRANS-
FORMER
J4
N.F.
N.A.
X2
T1
X2
J3
J5
H2
FAN
1
H2
FAN
FAN
FAN
SOL
1 2 3
4
10
1 2 3 4
5 6
5 6
9
7
8
TS1
THERMOSTAT
LOCATED
CAP-
CAP+
SOL
GAS
SOLENOID
TMP
TMP
IN
T
RANSFORMER
544A
543A
N.G.
NOTES:
N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT
J6 N.C.
1
J4
J4
COMPOUND (DOW CORNING 340) WHEN REATTACHING.
P3 N.C.
1 2 3 4 5
P4, N.C.
1 2
P5 N.C.
1 2 3
N.B. WORK AND GUN CONNECTIONS SHOWN FOR GMAW WELDING.
N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTION SIDE
OF CONNECTORS.
2
3
1 2 3 4
120V
1 2 3 4
230V
N.D. J4 IS DETERMINED BY MACHINE'S INPUT VOLTAGE.
N.E. THIS COMPONENT IS "S1" FOR TAPPED MACHINES AND "R2" FOR
CONTINUOUS MACHINES.
4
4 5 6
6 7 8 9 10
3 4
N.F. SEE S26766 FOR SPOT TIMER KIT WIRING DIAGRAM.
N.G. SEE M20410-1 FOR SPOOL GUN KIT WIRING DIAGRAM.
LATCH
ELECTRICAL SYMBOLS PER E1537
IDENTITY PLUG CONFIGURATION
B
M20410
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.
cOmpacT WirE WElDErS
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G-3
G-3
ElEcTrical DiaGramS
WiriNG DiaGram - SpOOl GuN iNTErfacE OpTiON - (m20410-1)
SPOOL GUN INTERFACE - WIRING DIAGRAM
P5 J8
WARNING
4A
4
Do not operate with covers removed.
D
isconnect input power by unplugging
power cord before servicing.
2A
2
Do not touch electrically live parts
543A
544A
Only qualified persons should
use or service this machine.
install,
HIGH VOLTAGE
can kill
MOTA1
N.H.
MOTB
P8
4
544A
R1
NOTE:
MOTA2
MOTOR A
:
INTERNAL MACHINE WIRE DRIVE
SPOOL GUN
N.F.
MOTOR B
:
2
MOTB
J7 P3
P7
SPOOL GUN
CAP+
SOL2
CAP+
SOL2
TMP2
TMP1
MOT-
MOTA2
SOL1
GND
TMP2
TMP1
MOT-
MOTA1
SOL1
GND
N.G.
1 2 3 4
CAP-
CAP-
1
2 3 4
PLUG AND
L
EAD ASSEMBLY
N.G.
NOTE POLARITY
WORK
NOTES:
N.A BOLTED ALUMINUM CONNECTIONS REQUIRE
COMPOUND DOW CORNING 340) WHEN REATTACHING.
WORK AND GUN CONNECTIONS SHOWN OR GMAW WELDING.
ROM NSERTION SIDE
.
T12837 JOINT
(
J6 N.C.
1
J4
J4
N.B
.
F
F
P3 N.C.
1 2 3 4 5
P4
,
N.C.
P5 N.C.
1 2 3
N.C
.
CAVITY NUMBERING SEQUENCE VIEWED
I
1 2
OF
CONNECTORS.
N.D
.
J4
I
S DETERMINED BY MACHINE'S INPUT VOLTAGE.
2
3
1
3
1
3
2
4
2
4
N.E
.
T
HIS COMPONEN
T
IS "S1"
FOR
T
APPED MACHINES AND "R2" FOR
4
CONTINUOUS MACHINES.
SEE S26766 OR SPOT TIMER KIT WIRING DIAGRAM.
SEE M20410 OR MACHINE WIRING DIAGRAM.
SHOWN N "SPOOL GUN" POSITION.
4 5 6
6 7 8 9 10
3 4
N
.F
N.G
N.H
.
F
F
.
120V
230V
LATCH
.
I
ELECTRICAL SYMBOLS PER E1537
IDENTITY PLUG CONFIGURATION
M20410-1
B
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.
cOmpacT WirE WElDErS
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G-4
G-4
ElEcTrical DiaGramS
WiriNG DiaGram - cOmplETE machiNE - cODE 11444 ONly - (m20410-2)
WIRING DIAGRAM
WARNING
N.G.
Do not operate with covers removed.
WORK
Disconnect input power by unplugging
power cord before servicing.
SPOOL GUN
(OPTIONAL)
Do not touch electrically live parts
N.B.
Only qualified persons should install,
use or service this machine.
MOTOR
HIGH VOLTAGE
can kill
EITHER
6A
GUN
WIRE FEED MOTOR
MOT+
MOT-
1A
BLUE OR
BLACK EAD
J6
P6
L
2A
1
4A
543A
544A
5
6
CB1
S1
BROWN OR
RED LEAD
GND
TS2
OUTPUT
CHOKE
6
TO
EARTH
GROUND
ER NATIONAL
LOCAL OR OTHER
APPLICABL
ELECTRICAL
CODES
FAN
H1
N.A.
N.A.
P
,
X1
H1
CAPACITOR
C1
X1
E
D1
TRANS-
FORMER
.
J4
N.F.
GREEN OR
N.A.
YELLOW
L
E
AD
X2
T1
X2
J3
J5
H2
FAN
1
H2
FAN
FAN
SOL
FAN
SOL
1 2 3
4
10
1 2 3 4
5 6
5 6
9
7
8
TS1
THERMOSTAT
CAP-
CAP+
TMP
TMP
GAS
SOLENOID
LOCATED IN TRANSFORMER
544A
543A
N.G.
NOTES:
N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT
J6 N.C.
1
COMPOUND (DOW CORNING 340) WHEN REATTACHING.
P3 N.C.
1 2 3 4 5
P4, N.C.
1 2
P5 N.C.
1 2 3
N.B. WORK AND GUN CONNECTIONS SHOWN FOR GMAW WELDING.
N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTION SIDE
OF CONNECTORS.
2
3
4
4 5 6
6 7 8 9 10
3 4
N.F. SEE S26766 FOR SPOT TIMER KIT WIRING DIAGRAM.
N.G. SEE M20410-1 FOR SPOOL GUN KIT WIRING DIAGRAM.
LATCH
ELECTRICAL SYMBOLS PER E1537
M20410-2
B
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.
cOmpacT WirE WElDErS
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G-5
G-5
ElEcTrical DiaGramS
WiriNG DiaGram -cOmplETE machiNE - cODE 11442 ONly - (m20410-3)
WIRING DIAGRAM
WARNING
SPOT TIMER
M20961-2
J1
Do not operate with covers removed.
Disconnect input power by unplugging
power cord before servicing.
WORK
P5
J5
Do not touch electrically live parts
N.D.
N.B.
Only qualified persons should install,
use or service this machine.
HIGH VOLTAGE
can kill
THERMAL
LED
6A
FILTER PCB
GUN
WIRE FEED MOTOR
MOT+
MOT-
1A
BLUE
LEAD
J6
P6
2A
4A
V
1
6
543A
544A
U
5
CB1
S1
BROWN
LEAD
GND
TS2
OUTPUT
CHOKE
L13344-1
CONTROL BOARD
6
FAN
H1
TO
GROUND
ER NATIONAL
LOCAL OR OTHER
APPLICABL
ELECTRICAL CODES
EARTH
N.A.
N.A.
X1
H1
CAPACITOR
C1
P
,
X1
D1
E
.
TRANS-
FORMER
J4
(GREEN/YELLOW
LEAD)
N.A.
X2
T1
X2
J3
J5
H2
FAN
1
H2
FAN
FAN
FAN
SOL
1 2 3
4
10
1 2 3 4
5 6
5 6
9
7
8
TS1
THERMOSTAT
CAP-
CAP+
SOL
GAS
TMP
TMP
SOLENOID
LOCATED IN TRANSFORME
R
544A
543A
J6 N.C.
NOTES:
N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT
P3 N.C.
1 2 3 4
P4, N.C.
1 2
P5 N.C.
1 2 3
5
1
COMPOUND (DOW CORNING 340) WHEN REATTACHING.
2
3
N.B. WORK AND GUN CONNECTIONS SHOWN FOR GMAW WELDING.
N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTION SIDE
OF CONNECTORS.
N.D. PIN NEAREST THE FLAT EDGE OF LED LENS ALIGNS WITH
WHITE LEAD OF LED SOCKET.
4
4 5 6
6 7 8 9 10
3 4
LATCH
ELECTRICAL SYMBOLS PER E1537
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.
cOmpacT WirE WElDErS
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G-6
G-6
ElEcTrical DiaGramS
SchEmaTic - cOmplETE machiNE m21240
0 4 2 1 M 2
ENGI
NEERING CONTROLLED
CHANGE
DETAIL: UPDATED FO
R
CE MACHI
NE.
MANUFACTURER: No
208/230v
But, at 208v
loading.
r
etail and
i
ndustrial
equire no
r
input.
input, the output
Two versions of INPUTS
180A units: 208/230v etail and
NEMA 6-50 plug, 20 amps normal (use 40 super
CONTROL P.C. BOARD
CONT
ROL P.C. BOARD
Same switch for
all machines
r
industrial
SECONDARY SIDE
P
RIMARY SIDE
D
ifferent cord and plug for both voltages
120 and 230 nput = 25A / 250VAC
i
(
)
lag)
D
if
f
erent case front and nameplate from
r
etail to
i
ndustri
a
l
versions.
Front Center
5
6
Top Front (lays fl t)
a
125A and 140A units: 120v
retail and industrial
Industri
al
v
ersion has aluminum extruded lifting handle and a
S1
CB1
(
NEMA 5-15 plug, 20 amps
)
Top Rear
plastic case back attached to the
r
ear sheet meta back.
l
Schematic: G4822
Industri
has a potted tray
Retail arly version :
are humi-sealed boar
Same blank ,dif erent
arts.
al
& Retail version :
A
ll measurements made with
respect to Board Common
203 at 4-J5 or 1-J3
e
d
f
p
A
ir flow is back to front
TS2
6
Voltage Control
Continuous Contr
(all versions of all units
)
voltage contr
ol
FAN
ol
= 10K ~ 2 to 5 vdc across pot. (industri
a
l
versions only)
H1
T
AP Contr
o
l
5 positions D to A =6.6v ( retail versions only)
fixed
urn-back
control
Trigger Status
B = 7.6v
C = 8.7 v
b
120V use
P.C. BD
+15vdc
D
if
and 230
Fan uns all the time
f
erent fan for 120
J4
Voltage Control
P4
input
F
= 9.8 v
FILTE
R
circuit
Right Front
r
O
N
CE MACHINES
G = 14.2 v
open= 15v
ONLY
CONTROLS ARE
BOARD MOUNTED
15vdc
regulator
and isol
Trigger
irc its
FAN
PWM
Control
Amplifier
230V use
C
u
Left Front
WF
S
10K ohms .7v to 9.1v
no tap control)
Can not change plug to
make work with dif erent
input power evels n the
field (factory use only)
PCBpower use
continuous control
(
19
-
30 VDC to run
f
i
203 Common
solenoid and one WFS
motor at a time
l
WFS Control
FET
MotorOverload
and Feedback
120V use
T1
opto
isolation
H2
SCR Control
= spot ti
= spoo gun options & wiring
= factory connections to contr bd.
mer option & wiring
FE
T
Contr
urns on after trigger
or fixed time.Three 5W,
esistor n par ll l.
o
ller bleeder
resistor
FA
1
N
+15VDC
PWM Control
and Overload
rotection
t
f
r
elease
l
a
Base Front below choke
stack for 125A version
TS1
P
51ohm
r
s
i
a
e
203
ol
3"
+15VDC
4" stack for 140 and 180 versions
A
Copper
for the 180, and
R
TH
E
RMAL LED
aluminum for the 125 and 140.
PM180C (
CE) VERSI
ON
ONLY
203
Trigger
from gun
Upper
Case Front
l
eft cor
ner of
J3
J5
10
5
6
7
4
9
when measuring fro
pin 2 to ground
m
2
3
1
8
S26766
OPE
N
= 0
V
P7
P9
harness plug
CLOSE
D
= 9.8
V
(timmer option)
+
M21182
harness plug
(spool gun option)
when measuring
between pins 1 and 2
OPE
N
= 15
V
= 0
CLOSE
D
V
timer option
Control Board
Trigger Circuit
OPTIONAL
SPOT TIMER
P.C. BOARD
J9
P8
P1
J1
OPE
N
= 0
V
Schematic M20960-1, -2 (C
E
VERSI
ON)
CLOSE
D
= 13.8
V
Top Rear
Solenoid not found
in 125A
retail units.
spool
gun
Must order
kit and
i
nstall
.
wir
e
reel center panel area
option
GAS
SOLENOID
+15VDC
+15VDC
12vdc
rated 22 ohms
P
ull = 12vdc, Hold = 6vdc
w
ir
e
reel center panel area
spoo
option
l
gun
Spool-gun/
Logic
Spot im
Full CCW
= OFF
overload protected by PC board.
Shut off s approx. 1.25A of current draw
open circui
typically equals
board input volts
t
J7
P3
9
8
8
6
6
J8
P5
7
2
2
3
3
5
4
4
10
10
1
1
standard gun
witch
(option
CW
T
e
i
s
)
9
7
5
standar
use plug-in
d
shown in std. gun position
Adjusts from
200mS to 10S
CCW
Toolless Drive Roll Change Over
wist ock type drive ll etainer
nner / outer ire slide guide
BOARD POWER
T
i
l
r
o
r
clip.
w
Load compensated type control for this
motor. Does not tend to stall if liner is
Comes with unit
:
.025 smooth
.035 smooth
clogged like in older small SP’s.
WFS Range :
50 to 500 + pm
1.5 to 12.5 vdc
Wound
TMP main transfor
(n n-replaceable)
N.C.
inside of
mer
Feeder
Motor
i
TMP
.030/.045 knurled
o
Retail
gear front housing.
Industri
housing
version has a plastic
C
urrent Limit to approx 2.5 amps
brass
bushing
right side
Duty Cycle (retail
180 amp unit
0% duty 130 amps @ 20 v
&
industrial):
right front (for
w
ardstud)
a
l
v
ersion has a metal
:
ELECTRODE
19
-
30 VDC to
solenoid and one WFS
motor at a time
r
un
CHOKE
below pc board
(
sil er n color).
v
i
Gear Box
3
same thermostat on all machines
d
230v
if
f
erent bridge for
OC
V
RANGE
30 to 180 amps
OCV = 33 vdc
input versions
(aluminum)
10 - 35V (IN
P
UT VOLTAGE DEPENDENT)
TRIGGER
140 amp unit
:
BACK O
(onCEversion only)
F
OUTPU STUD
T
base ar
r
e
20% duty 90 amps @ 19.5v
AC
right outer plate
AC
D1
MAI
BRIDG
C1
59,000mf/50vdc fpr 120v
120,000mf/50vdc fpr 230v inpu
PUT CAP
i
s
30 to 140 amps
OCV = 33 vdc
125 amp unit
N
left outer plate
E
use one or the other but
not both at the same time
OUT
C
OMPONENT
CAPACIT R: MFD/
RESIST R: HMS/
V
AL
U
E
U
NITS:
OLT
ATT
LE
A
D
C
OL
O
R
CODE:
:
2
0% duty 90 amps @ 19vdc
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-
Y-
O
V
S
W
4
2
30 to 125 amps
OCV = 32 vdc
O
O
W
S
TRIGGER
W
1
4
+
-
left andright side
rear area
R
B
CONNECT
OR
PIN
NUMBERS:
2
3
543A
Use Do Corning
w
WORK
right front (rear stud)
joint compound
(T12837) to
MOTOR
W
Y
HIT
ELLOW
E
EX. 12 PIN CONNECTO
R
544A
2
1
7
6
reconnect cap
lower case front
Spool-gun option K2532-1
Magnum 100 SG
LABELS:
OMMON
FRAM GROUND
EART GROUND
LINCOLN GLOBAL, INC. AND MA
Same motor control
circuits, but for a smaller
motor
J6
C
12
LATCH
E
H
VIEW OF CONNECTOR ON PC BOARD
PROPRIETARY &
CONFIDENTIAL:
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
Y
NOT BE DUPLICATED, COMMUNICATED
PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
TO OTHER PARTIES OR USED FOR AN
CONTROL: CLEVELAND
SCA E:
0.5 mm)
Y
M
ANUFACTURING TO
L
ERANC
E
P
ER
E2056
L
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIPMENT TYPE:
SMALL
1
1
W
IRE FEEDE
R
WELDERS
PAGE ___ OF ___
ON
ON
ON
2
3
A
PLAC
PLACE
LL ANGL
TO
LISHED STANDARDS.
E
D
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
S
±
00
A
.02 in.
(
±
NONE
DRAWN BY:
ENGINEER:
APPROVED:
cstuble
D
E
±
.
2
DE
TO
i
n.
GREE
GREE
(
±
0.
0
5
mm)
DOCUMEN
REVISION:
T
DOCUMEN
NUMBER:
T
IF PRIN
SIZ
T
ED
E
E
L
S
I
S
±
SUBJECT:
MA ERIAL
MACHINE SCHEMATIC
REFERENCE:
@
A
1
MATERI
A
L
E
"
)
A
B. STELLER
t
UNITS:
WITH PU
B
T
APPROVA
DATE:
L
PROJEC
NUMBER:
T
M21240
NA
6/6/2008
D
Insight
CRM39439
.
DISPOSI ION:
T
INCH
DO NO
T
SCAL HIS DR
E
T
AWING
-
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
cOmpacT WirE WElDErS
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G-7
G-7
ElEcTrical DiaGramS
SchEmaTic - machiNES WiTh vOlTaGE cONTrOl SWiTch - (G4741-1)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
cOmpacT WirE WElDErS
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G-8
G-8
ElEcTrical DiaGramS
SchEmaTic - machiNES WiTh cONTiNuOuS vOlTaGE cONTrOl (G4822-1)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
cOmpacT WirE WElDErS
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G-9
G-9
ElEcTrical DiaGramS
SchEmaTic - filTEr pc bOarD aSSEmbly - (S24206-2)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
cOmpacT WirE WElDErS
Download from Www.Somanuals.com. All Manuals Search And Download.
|