Lincoln Electric IM467-B manual Troubleshooting Guide Stick Welding, Symptom Cause and Remedy

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TROUBLESHOOTING

E-2

 

 

 

 

TROUBLESHOOTING GUIDE

STICK WELDING

Observe Safety Guidelines detailed throughout this manual.

 

SYMPTOM

 

CAUSE AND REMEDY

 

 

Machine shuts off in Stick mode.

1.

Welder has overheated and secondary thermostat has

 

 

 

 

opened. Allow welder to cool before attempting to turn

 

 

 

 

on. Be sure to provide adequate ventilation around

 

 

 

 

welder to prevent recurrence.

 

 

 

 

 

 

 

Stick electrode “blasts off” when touched

1.

Weld current is set too high for electrode size. Reduce

 

 

 

 

weld

 

 

to workpiece.

 

current.

 

 

 

2.

Start Switch is “On”, and Start Current is set too high

 

 

 

 

for electrode size. Either turn Start Switch OFF, or

 

 

 

 

reduce Start Current.

 

 

 

3.

Arc Force control is set too high. Turn to minimum.

 

 

 

 

 

 

 

Arc seems too hot, and reducing current

1.

Arc Force control is set too high. Turn to minimum.

 

 

potentiometer does not help.

2.

Start Switch is ON and Start Current is set too high.

 

 

 

 

 

 

 

Start time may be set too long. Reduce or turn Start

 

 

 

 

Switch OFF.

 

 

 

 

 

 

Machine welds at very low output, regard-

1. Current Control switch is in REMOTE. Switch to

 

 

less of Current potentiometer setting.

 

LOCAL.

 

 

2.

Start Switch is ON, and Start Current is set too low for

 

 

 

 

 

 

 

the electrode size. Either turn Start Switch OFF, or set

 

 

 

 

Start Current to proper level for the electrode size.

 

 

 

3.

Does machine have correct output in TIG mode? If not,

 

 

 

 

see “Machine welds at low output” in TIG troubleshoot-

 

 

 

 

ing section.

 

 

 

4.

If TIG welding output is OK, Control PC board is defec-

 

 

 

 

tive. Replace.

 

 

 

 

 

 

Machine welds at very high output, regard-

1. Are the Start controls set correctly? See “Stick elec-

 

 

 

 

trode

 

 

less of Current potentiometer setting.

 

blasts off” above.

 

 

 

2.

Are the TIG welding outputs OK? If not, see TIG trou-

 

 

 

 

bleshooting section.

 

 

 

3.

If TIG welding output is OK, Control PC board may be

 

 

 

 

defective. Replace.

 

 

 

 

 

 

 

Arc Force control has no effect.

1.

The effect of the Arc Force Control will be less notice-

 

 

 

 

able at high welding currents. Weld at low current (less

 

 

 

 

than 150 amps) and check Arc Force effect.

 

 

 

2.

If no effects are seen at low currents, the Arc Force

 

 

 

 

control potentiometer may be defective. Replace.

 

 

 

3.

Control PC board may be defective. Replace.

 

 

 

 

 

 

Gas and water do not flow even though Gas

Machine is operating properly; gas and water solenoids, as

 

 

 

 

well as

 

 

and Water LED is lit in Stick mode.

the high frequency circuit, are disabled in the Stick mode.

 

 

 

 

 

 

WARNING

This Troubleshooting Guide is designed to be used by the machine Owner/Operator. 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, please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment.

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SQUARE WAVE TIG 355

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Contents Square Wave TIG Safety Electric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Thank You Table of Contents Section D Section CSection E P196 SeriesTechnical Specifications Square Wave TIG InstallationHigh Frequency Interference Protection Safety PrecautionsSelect Suitable Location Ground Connection Input ConnectionsInput Supply Connection Electric Shock can killFigure A.2 Input Supply Connections Reconnect ProcedureTable A.2 Recommended Input Wire and Fuse Sizes Table A.1 Recommended Input Wire and Fuse SizesVolt/Freq Nameplate AWG Copper Cond Volt/Freq AC Output AWG Copper CondTIG Torch Connection Output ConnectionsLengths up to 100 to 200 ft 200 to 250 ft 100 ft 30 m 30 to 61 m 61 to 76 mStick Electrode Cable Connection Operating Instructions Safety InstructionsDesign Features and Advantages Operational Features and ControlsGeneral Description Recommended ProcessesLimitations Welding CapabilityUpper Case Front Controls Controls and SettingsSTEP/4-STEP Switch Mode SwitchHigh Frequency Switch Upper Case Front Control PanelPeak Current Control VOLTS/AMPS SwitchAC Wave Balance Auto Balance LEDStart Controls Spot ControlsPulse Controls Crater Fill Controls Figure B.2 Status Indicator Light Sequence Square Wave TIGOperation Figure B.3 Lower Case Frontcontrols Square Wave TIG Lower Case Front ControlsOperation Hand and Foot Amptrol Operation Operation Initial START-UP Welding OperationStick Welding TIG Welding GuidelinesTable B.1 Specific Effects of Controls Illustrated in the 2-Step Mode for clarityOFF Crater Fill Switch onPulse Switch on Crater Fill Switch on Start Switch onSpot Switch OFF Spot Switch onDcen Dcep + Unbalanced Wave Balanced Wave Table B.2 Typical Current RANGES1 for Tungsten ELECTRODES2TIG Welding Sequence Operation 4-STEP Mode TIG Welding Sequence Operation 2-STEP ModeTable B.3 Recommended Settings for TIG Welding Polarity SwitchALL Machines Auxiliary PowerOverload Protection OPTIONS/ACCESSORIES AccessoriesInput Power Factor Capacitor Discharge Procedure MaintenanceRoutine and Periodic Maintenance Figure D.2 General Component Locations General Machine Trouble Troubleshooting GuideSymptom Cause and Remedy Troubleshooting Guide Stick WeldingTroubleshooting Guide TIG Welding TIG Welding Lower Panel Controls K870 Foot Amptrol or K963 Hand Amptrol AccessoriesDiagrams Dimension Print Square Wave TIG355 Equipment MANUFACTURER’S Certification Equipment Installation CertificationPage Precaucion Aviso DE