IM1044

LN-442

OPERATOR'S MANUAL The LINCOLN machine covered by this manual is CEmarked and is in conformity with:- COUNCIL DIRECTIVE of May 3, 1989 on theapproximation of the law of the Member States relatingto ElectroMagnetic Compatibility (89/336/EEC).- COUNCIL DIRECTIVE of February 19, 1973 on theharmonization of the laws of the Member States relatingto electrical equipment designed for use with lowvoltage limits (73/23/EEC).This LINCOLN machine is manufactured in conformitywith the following European standard that implement aharmonized standard:- EN50199 Electromagnetic compatibility and applicablestandards of the EN 60974 serie.

LINCOLN ELECTRIC FRANCEAvenue Franklin Roosevelt

76121 Le Grand Quevilly cedexFrance

Tél : 02 32 11 40 40Fax : 02 32 11 40 11www.lincolnelectric.fr

IM 1044 - TABLE OF CONTENTS

TABLE OF CONTENTS

Eectromagnetic Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3

Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4

Presentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 5

Drive rolls and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 7

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 8-11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 12

trouble shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 13-15

Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16

Spare parts

IM 1044 - ELECTRO-MAGNETIC COMPATIBILITY

- 3 - LN 442

Electromagnetic Compatibility (EMC)

This machine has been designed in accordance with all relative directives and norms. However, it may still gene-rate electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, andtelevision) or other safety systems. These disturbances can cause safety problems in the affected systems. Readand understand this section to eliminate or reduce the amount of electromagnetic disturbance generated by thismachine.

WARNING: This machine has been designed to operate in an industrial area. To operate in adomestic area it is necessary to observe particular precautions to eliminate possible electromagne-tic disturbances. The operator must install and operate this equipment as described in this manual.If any electromagnetic disturbances are detected the operator must put in place corrective actions toeliminate these disturbances with, if necessary, assistance from Lincoln Electric. Do not modify thismachine without the written approval of Lincoln Electric.

Before installing the machine, the operator must check the work area for any devices that may malfunction becau-se of electromagnetic disturbances. Consider the following.* Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and themachine.* Radio and/or television transmitters and receivers.* Computers or computer controlled equipment.* Safety and control equipment for industrial processes.* Personal medical devices like pacemakers and hearing aids.* Equipment for calibration and measurement.* Check the electromagnetic immunity for equipment operating in or near the work area. The operator must besure that all equipment in the area is compatible. This may require additional protection measures.* The dimensions of the work area to consider will depend on the construction of the area and other activities thatare taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.* Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary totake additional precautions such as filtering the input supply.* The output cables should be kept as short as possible and should be positioned together.* If possible connect the work piece to ground in order to reduce the electromagnetic emissions. The operatormust check that connecting the work piece to ground does not cause problems or unsafe operating conditions forpersonnel and equipment.Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for specialapplications.

IM 1044 - SAFETY

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury, loss of life, or damage tothis equipment. Protect yourself and others from possible serious injury or death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this equipment. Arc weldingcan be hazardous. Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage tothis equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the electrode, work clamp, orconnected work pieces when this equipment is on. Insulate yourself from the electrode, work clamp, and connected workpieces.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to health. Avoid breathingthese fumes and gases. To avoid these dangers the operator must use enough ventilation or exhaust to keep fumes and gasesaway from the breathing zone.

ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of thearc when welding or observing. Use suitable clothing made from durable flame-resistant material to protect you skin and that ofyour helpers. Protect other nearby personnel with suitable, non-flammable screening and warn them not to watch the arc norexpose themselves to the arc.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area and have a fire extinguisherreadily available. Welding sparks and hot materials from the welding process can easily go through small cracks and openings toadjacent areas. Do not weld on any tanks, drums, containers, or material until the proper steps have been taken to insure thatno flammable or toxic vapors will be present. Never operate this equipment when flammable gases, vapors or liquid combus-tibles are present.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the fuse box before working onthis equipment. Ground this equipment in accordance with local electrical regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp cables. If any insulation dama-ge exists replace the cable immediately. No not place the electrode holder directly on the welding table or any other surface incontact with the work clamp to avoid the risk of accidental arc ignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any conductor creates electric andmagnetic fields (EMF). EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult theirphysician before operating this equipment.

CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the correct shielding gas for the pro-cess used and properly operating regulators designed for the gas and pressure used. Always keep cylinders in an upright posi-tion securely chained to a fixed support. Do not move or transport gas cylinders with the protection cap removed. Do not allowthe electrode, electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be loca-ted away from areas where they may be subjected to physical damage or the welding process including sparks and heatsources.

WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and materials in work area cancause serious burns. Use gloves and pliers when touching or moving materials in the work area.

CE COMPLIANCE: This equipment complies to the European Communities directives.

ATTENTIONThis equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair procedures are performed only byqualified individuals. Read and understand this manual before operating this equipment. Failure to follow the instructions in this manual could causeserious personal injury, loss of life, or damage to this equipment. Read and understand the following explanations of the warning symbols. LincolnElectric is not responsible for damages caused by improper installation, improper care or abnormal operation.

- 4 - LN 442

IM 1044 - LN 442 WIRE FEEDER - DESCRIPTION

- 5 - LN 442

Duty cycleThe LN 442 2-roll and the LN 442 4-Roll are rated at60% duty cycle (1) for a maximum current of 500 Amps.

(1) Based on 10 minute time period at 6 minutes on and4 minutes Off.

Description

The LN 442 wire feeder is designed for use with aconstant voltage DC power source. It is a stabilized speed wire feeder developedspecifically for MIG/MAG welding and shield gas fluxcored welding processes.

Powered by a 42 volt motor drive system, the LN 442are available in 2 versions

LN-442 2-roll & 4-roll have 2 operation modes:- 2-step trigger- 4-step trigger

Two functions can be selected:- Arc voltage- Welding Amps. (through wire feed speed con-

trol A).

Drive roll and guide-tube kits :

See page 7, drive roll and guide-tube paragraph.

Water connection kit

See paragraphe “Water connection” page 9.

Technical features of LN 442 wire feeder

See page 10 “Technical features”

Oberve all safety rules before, during andafter welding

K number Roll Wire speed range wire size

K10308-1 2-Roll 2 - 20 m/min. 0.6 - 1.6mm

K10305-1 4-Roll 2 - 20 m/min. 0.6 - 1.6mm

Wire feeding capabilitie

The 2 and 4-roll LN 442 have the following wire feedingcapabilities :

• Feeds .035 - 1/16” ( 0.8 to 1.6mm), solid wire for gas-metal-arc-welding (MIG/MAG). • Feeds .045 - 1/16” ( 1.0 to 1.6mm), aluminium wire forMIG welding. • Feeds ..035 - 1/16” (0.8 to 1.6mm), shielded gas fluxcored wire

Connecting the welding gun

1) Position the connection points on the gun cableconnector to correspond with the connector and insertwith a gentle push.

2) Screw the threaded collar clockwise to firm contact.

Work Cable

Connect a work lead of sufficient size and length (perthe following table) beetwen the proper output stud onthe power source and the work. Be sure the connectionto the work makes tight metal-to-metal electricalcontact.

(70mm2)

(70mm2)

(95mm2)

(70mm2)

(95mm2)

(95mm2)

IM 1044 - OPTIONS & ACCESSORIES

- 6 - LN 442

Drive Roll and Guide Tube Kits:

2-roll wire feeder 4-roll wire feederSteel Wire Sizes: .

.035-.045” (0.8-1.0mm) Solid KP10280-1.0 KP10281-1.0

.045-.052” (1.0-1.2mm) Solid KP10280-1.2 KP10121-1.2

.052-1/16” (1.2-1.6mm) Solid KP10280-1.6 KP10281-1.6

Cored wire size - Knurled roll.052-1/16” (1.2-1.6mm) KP10280-1.6C* K10281-1.6C*

Aluminium wire.045-.052” (1.0-1.2mm) KP10280-1.2A** KP10281-1.2A**.052-1/16” (1.2-1.6mm) KP10280-1.6A** KP10281-1.6A**

* Knurled drive rolls are stencilled with an “R” suffix to the wire sizes

** Drive rolls for aluminium wire sizes are stencilled with an “A” suffix to the wire sizes

K590-2 Water connection kit for water cooled torch.Use the control and weld cable bundle listed below.

K10329 MAGNUM 10 I, water cooling unit, 8 litres.

K10182-6 Presssure regulator.

K10309-1 Voltmeter/Ammeter display

Welding torches

K10244-3M MIG/MAG torch, 400A, 60%, air cooled,1,2mm diameter, 3 meters long..

K10245-3M MIG/MAG torch, 500A, 60%, air cooled,1,6mm diameter, 3 meters long.

K10157-4M MIG/MAG torch, 500A, 100%, air cooled,1,2mm diameter, l4 meters long.

K10158 Molded plastic adapter for 15 Kg spool &Readi-reel.

Options & Accessories

IM 1044 - WATER & GAS CONNECTIONS & TECHNICAL FEATURES

- 7 - LN 442

CYLINDER may explode if damaged.Keep cylinder upright and chained tothe machine.• Keep cylinder away from areas

where it may be damaged.• Never allow welding electrode to

touch cylinder• Keep cylinder away from welding or

other live electrical circuits.

BUILDUP OF SHIELDING GAS mayharm or kill

• Shut off shielding gas supplywhen not in use

WARNING

ATTENTION

GAS CONNECTION

1: With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the outletand open the cylinder valve very slightly for aninstant. This blows away any dust or dirt whichaccumulated in the valve outlet.

2: Attach the flow regulator to the cylinder valve andtighten the union securely with a wrench

ATTENTION

WATER CONNECTION

CV 450T / LN 442 package without water connectionkit.

If you wish to have your wire feeder equiped with waterconnection kit, order the following :• K590-2 Water connection kit. • Interconnecting cables (include water hoses). • K10329 Magnum water cooler, 8 litres, 400A.

For more information, contact your nearest Lincolndistributor or Lincoln France Spare Parts DepartmentTel. (33) 2 32 11 40 50.

Material included in the package.

• 5 meter input cable less plug.• 5 meter work lead with clamp.

BE SURE TO KEEP YOUR FACE AWAY FROM THEVALVE OUTLET WHEN “CRACKING” THE VALVE.

Always stand to one side

IM 1038 - TECHNICAL FEATURES

LN 442 wire feeder

• Wire speed range

• Wire size capability- Solid & cored wire- Aluminium wire

• Control voltage

• Operating T°

• Storage T°

2 - 20 meter per minute

0,8 - 1,6mm1,0 - 1,6mm

42V +/- 10%, 50-60Hz

-20°C à +40°C

-40°C à +40°C

IM 1044 - OPERATION

-18 - LN 442

LN 442 Wire Feeder - Output controls

A. Wire feed speed potentionmeter

Potentiometer with continuous setting, graduated from 1to 10 for the control of wire feed speed.

B. Trigger mode selection1. 2-Step trigger mode : In the UP position, 2-stepswitch is selected. Trigger closure energizes thesolenoïd valve , then wire feeder and power source. Releasing the trigger, turn off the the wire feeder, andthe power source & solenoïd valve.2. 4-Step trigger mode : In the DOWN position, 4-Stepmode is selected. Trigger closure energizes only thesolenoïd. Trigger release energizes the wire feeder andthe power source. Closing the trigger a second time turn off the wire feed-er, then the power source. Releasing the trigger turns offthe solenoïd valve.

C. Gas purgePushing on this button energizes the solenoïd valve andblow out air in the circuit and allows the arc to be struckunder good shielding gas condition.

D. Water connections for Water cooled torch(for LN 442 with water solenoïd kit installed K590-2 -see page 13, options & accessories)Connect appropriate water cooled torch hoses to theinlet and outlet in front of the LN 442. Connect the otherends of these hoses to the appropriate ports on yourwater cooling unit.

E. Cold InchWhen pushed on, Cold inch energizes the wire feederbut not the power source or solenoïd valve. The wire,then, feeds at inch speed without gas. This control isused to insert the welding wire in the torch.

F. Euroconnector for European weldingtorch.Gun connector enables the connection of welding gunto the wire feeder euroconnector and allows passingthrough of electrode wire, protection gas and controlcable of the gun. Connect gun to Euroconnector making sure all pins andgas tube line up with appropriate holes in connector.Tighten gun by turning large nut on gun clockwise.

• Stabilized Wire drive system.Enables the control of wire feed speed through regula-tion of motor input current.

A

B

C

D(optional)

E

F

IM 1044 - OPERATION

LN 442

POWER SOURCE

Interconnecting cables

Power lead

Control cable

Input cable.

Pressureregulator

Gascylinder

Euroconnector

Brass blockHex. Hd screw

Mig/Mag weldingtorch

Work lead

MagnumWater Cooler

water hose

water hosegas hose

- 9 - LN 442

IM 1044 - OPERATION

- 10 - LN 442

PRELIMINARY OPERATIONS - LN 442 2-roll

Once a gas cylinder has been securely held on themachine, connect the gas hose of the input cable to thegas cylinder using a pressure regulator.

Open the cover of the machine so the hub assembly

and the wire drive unit are accessible.

Mount the wire spool on the hub assembly in such away that, by dragging outer extremity of the wire, thespool turns round clockwise; make sure that the refer-ence projecting on the hub assemly goes into the fittinghole. Check if the driving roll bears stamped on theouter side the diameter corresponding to the wire used.Otherwise, unscrew the screw holding the roll and turn itor replace it. Every roll is provided with two grooves fitted for thefeeding of wire with different diameters. Special rollsare available for cored wires and aluminium. Release by the suitable lever the pressure roll turningon the ball bearing and lift it. Put the wire inside the fit-ting inlet guide and let it out through the torch adapter.Lower the lever regulating the pressure by the adjust-ment nut(s). The best thing is to keep the right pressure as it avoidsany roll slipping. An excessive pressure causes wiredistorsion, entanglements at the protection entry andthe early wear and tear of the feeding motor. Too low a pressure may cause welding irregularities.Connect the gun to the gun adaptor and make sure thewire runs correctly inside the liner of the gun cable. .Take off the gas guide from the gun extremity andunscrew the contact tip. Make the wire come forward as far as it comes out ofthe gun. Mount again the contact tip keeping in mindthat it must correspond, regarding the diameter, to thediameter of the wire used. Mount again the gasguide nozzle. Connect the earthconnection clamp to the work piece to weld or to thewelding table, making sure that the clamp is providedwith a good quality contact. In order to be sure the

good contact quality, surface of the work piece mustbe clean and must not show any rust, paint or oilystains.

ATTENTIONWhen inching with gun trigger, electrode and drivemechanism are live to work and ground.

Idle Roll

Driving Roll

Adjustment nut

Inlet guide tube

LN 442 2-RollWire drive assembly

Pressure regulator

Gas hose

IM 1044 - OPERATION

- 11 - LN 442

PRELIMINARY OPERATIONS - LN 442 4-roll

Once a gas cylinder has been securely held on themachine, connect the gas hose of the input cable to thegas cylinder using a pressure regulator.

Open the cover of the machine so the hub assemblyand the wire drive unit are accessible.

Mount the wire spool on the hub assembly in such away that, by dragging outer extremity of the wire, thespool turns round clockwise; make sure that the refer-ence projecting on the hub assemly goes into the fittinghole. Check if the driving roll bears stamped on theouter side the diameter corresponding to the wire used.Otherwise, unscrew the screws holding the rolls andturn it or replace them. Every roll is provided with two grooves fitted for thefeeding of wire with different diameters. Special rollsare available for cored wires and aluminium. Turning the adjustment nut, remove the pressure on theball bearings and lift them. Put the wire inside the fittinginlet guide and let it out through the gun adapter. Lowerthe lever and put the pressure back on the bearingswith the adjustment nut. The best thing is to keep the right pressure as it avoidsany roll slipping. An excessive pressure causes wiredistorsion, entanglements at the protection entry andthe early wear and tear of the feeding motor. Too low a pressure may cause welding irregularities.Connect the gun to the gun adaptor and make sure thewire runs correctly inside the liner of the gun cable. .Take off the gas guide from the gun extremity andunscrew the contact tip. Make the wire come forward as far as it comes out ofthe gun. Mount again the contact tip keeping in mindthat it must correspond, regarding the diameter, to thediameter of the wire used. Mount again the gasguide nozzle. Connect the earthconnection clamp to the work piece to weld or to thewelding table, making sure that the clamp is providedwith a good quality contact. In order to be sure the

good contact quality, surface of the work piece mustbe clean and must not show any rust, paint or oilystains.

ATTENTIONWhen inching with gun trigger, electrode and drivemechanism are live to work and ground.

Idle Rolls

Adjusment nut

Inlet guide tubeDrivingRolls

LN 442 4-RollWire Drive Assembly

Pressure regulator

Gas hose

IM 1044 - MAINTENANCE

- 12 - LN 442

f) Replace contact tip when the arc starts to becomeunstable or the contact tip end is melted ordeformed.

g) Do not use excessive wire spindle brake settings.ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or internal wiring.• When inching with gun trigger, electrode and drive

mechanism are live to work and ground.• Turn OFF welding power source before installing or

changing drive roll/or guide tubes.• Welding power source must be connected to

system ground per the National Electrical Code andany applicable local code.

• Only qualified personnel should perform thisinstallation.

GENERAL MAINTENANCE 1. In extremely dusty locations, dirt may clog the air

channels causing the machine to run hot withpremature tripping of thermal protection. Blow outthe machine with low pressure air at regularintervals to eliminate excessive dirt and dust build-up on internal parts.

WARNING

ROUTINE MAINTENANCEDrive Rolls and Guide TubesAfter feeding every coil of wire, inspect the drive rollsection. Clean it as necessary. Do not use a solventfor cleaning the idle roil because it may wash thelubricant out of the bearing. The driver roll and guidetubes are stamped with the wire sizes they will feed. Ifa wire size other than that stamped on the roll(s) is tobe used, the roll(s) and guide tubes must bechanged.

Avoiding Wire Feeding ProblemsWire feeding problems can be avoided by observingthe following gun handling procedures:a Do not kink or pull cable around sharp corners.b) Keep the electrode cable as straight as possible

when welding or loading electrode through cable.c) Do not allow dolly wheels or trucks to run over

cables.d) Keep cable clean by following maintenance

instructions.e) Use only clean, rust-free electrode. The Lincoln

electrodes have proper surface lubrication.

PROCEDURE FOR REPLACING PC BOARDS Before replacing a PC board which is suspected ofbeing defective, visually inspect the PC board inquestion for any electrical or mechanical damage toany of its components and conductors on the back ofthe board.a. If there is no visible damage to the PC board, install

a new one and see if this remedies the problem. Ifthe problem is remedied, reinstall the od PC boardto see if the problem still exists. If it does no longerexist with old PC board:

1. Check the PC board harness connector pins forcorrosion, contamination, or looseness.

2. Check leads in the plug harness for loose orintermittent connection.

b. If PC board is visibly damaged electrically, beforepossibly subjecting the new PC board to the samecause of failure, check for possible shorts, opens,or grounds caused by˛

1. Frayed or pinched lead insulation.2. Poor lead termination, such as a poor contact or a

short to adjacent connection or surface.3. Shorted or open motor leads, or other external leads.4. Foreign matter or interference behind the PC boards.c. If PC board is visibly damaged mechanically, inspect

for cause, then remedy before installing areplacement PC board.

If there is damage to the PC board or if replacing PCboard corrects problem, return it to the local LincolnElectric Field Service Shop.

IM 1044 - TROUBLE SHOOTING GUIDE

- 13 - LN 442

Step 3. PERFORM COMPONENT TESTS.If you have exhausted all of the recommended tests inStep 2, Consult your Local Authorized Field ServiceFacility.

Step 1. LOCATE PROBLEM (SYMPTOMS).Look under the column labeled "PROBLEMS". This column describes possible symptoms that themachine may exhibit. Find the listing that bestdescribes the symptom that the machine is exhibiting.Step 2. PERFORM EXTERNAL TESTS.The second column labelled "POSSlBLE CAUSE" liststhe obvious external possibilities that may contributeto the machine symptom. Perform these tests/checksin the order listed. In general, these tests can be con-ducted without removing the case wraparound cover.

Observe all Safety Guidelines detailed throughout this manualHOW TO USE THE TROUBLESHOOTING GUIDEService and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician and machine operator and will invalidate yourfactory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautionsdetailed throughout this manual.

PROBLEMS POSSIBLE CAUSE WHAT TO DO

IF FOR ANY REASON YOU DO NOT UNDERSTAND THE TEST PROCEDURE OR AREUNABLE TO PERFORM THE TEST / REPAIRS SAFELY, CONTACT YOUR LOCAL LINCOLNAUTHORIZED FIELD SERVICE FACILITY FOR TECHNICAL TROUBLE SHOOTINGASSISTANCE BEFORE YOU PROCEED.

1. No possible setting of arcvoltage and / or wire feed speed

2 Rough wire feeding or wire notfeeding but drive rolls turning

0.Arc voltage control, Arc voltageselector and/or wire feed speed con-trol are in the wrong position

a. Gun cable kinked and/or twisted

b. Wire jammed in gun and cable

c. Incorrect position of drive roll withgrooves. d. Drive roll loosee. Gun cable dirtyf. Worn drive rollg. Electrode rusty h. Worn nozzle or cable lineri. Partialy flashed or melted contacttipj. Incorrect idle roll pressure

k. Improper liner, tip or guide tube

0. Put the control(s) in the rightposition.

a. Inpect gun cable and replace ifnecessaryb. Remove wire from gun and cable-Feed in new wire. Note any obstruc-tion in gun and cable. Replace gun and cable if necessary. c. See “Preliminary operations” page21 and 22.d. Remove, clean, install and tighten. e. Clean cable or replace linerf. Replaceg.Replaceh. Replacei. Replace contact tip

j. Set idle roll pressure according topage 12 or 13k. Install proper equipment

IM 1044 - TROUBLE SHOOTING GUIDE

- 14 - LN 442

PROBLEMS POSSIBLE CAUSE WHAT TO DO

3. Variable or hunting arc

4. Poor arc striking with stickingor “blast-offs”, weld porosity, nar-row and ropy looking bead, orelectrode stubbing into platewhile welding

5. Tip seizes in diffuser

7. Welding machine does notdeliver any current

8. Low current delivery and lowopen circuit voltage

9. Faulty welding results (porosity, spray, etc......)

a. Wrong size, worn and/or meltedcontact tipb. Worn work cable or poor workconnectionsc. Loose electrode

a. Improper gas shielding

a. Tip overheating due to pro-longed or excessive high currentand / or duty cycle welding

a. Power is missing

b. Faulty power source contactorc. Torch button does not work

d. Damaged rectifier of generatore. Faulty auxiliary transformer

a. Monophase workingb. Low line voltage

a. Faulty gas circuit

b. Bad quality of wire or gas used c. The work piece to weld are dirty

d. The earth is badly connected

e. Wrong adjustments of weldingvoltage and wire speed

f. The torch is faulty

a. Replace tip - remove any spatterand replace if necessaryb. Inspect - repair or replace asnecessary c. Be sure electrode lead is tight, guncable tight in wire feeder contactblock, gun nozzle and gun tip tight

a. Clean gas nozzle. Make certainthat gas diffuser is not restricted.Make certain that gas cylinder is notempty or turned off. Make certain thatgas solenoïd valve is operating andgas flow rate is proper. Remove gunliner and check rubbber seal for anysign of deterioration or damage. Besure set screw in brass connector isin place and tightened against theliner bushing.

a. Do not exceed current and dutycycle rating of gun. A light applica-tion of high temperature antiseizelubricant ( such as graphite grease)may be applied to tip thread.

a. Check the connection to the lineand remove any obstructionb. Replace it c. Check if the torch button close thecircuit, if it does not, replace it. d. Replace ite. Replace it

a. Check the line fuse b. check the input voltage

a. Check if the bottle tap is open Free the gas guide nozzle possibleobstructions. b. change the wire or gas qualityc. Clean the work piece

d. Check the earth clamp and see ifthe cable is whole and well closede. Increase or decrease theparameters so as to find the rightadjustmentf. Check the torch components and,if necessary, replace the faulty parts

IM 1044 - TROUBLE SHOOTING GUIDE

- 15 - LN 442

PROBLEMS POSSIBLE CAUSE WHAT TO DO

10. Drive roll does not turnalthough arc voltage is presentand solenoïd is on

11. Voltage adjust not functioningon the machine

10. Wire feed speed adjust notfunctioning on the machine

12. The wire is not fed

a. Defective wire feed motor

a. Arc voltage commutator

a. Wire feed speed potentiometer

a. The motor is damagedb. The feed rolls are worn outc. The contact tip is worn out

a. Replace wire feed motor.

a. Replace it.

a. Replace it

a. Check and if necessary replace itb. Replace itc Replace it

13. Machine has no output

14. Thermal protection indicatoris on.

15. Machine does not havemaximum output.

16. Machine will not shut off.

17. Variable or sluggish weldingarc.

1. Work lead loose or broken2. 4 A or 10 A fuse, inside themachine blown out3. Defective PC board

1. Protection thermostat has open.

1. Faulty P.C Board.

1.Defective power switch

1. Poor work connection.2. Welding lead size too small3. Arc voltage too low.

4. Defective SCR bridge 5. Wrong size, worn and/or meltedcontact tip.

1. Repair connection2. Check current and replace if everything normal. 3. See procedure for replacing PCboard.

1. Allow the machine to cool. Be sureto provide adequate ventilation formachine. Do not exceed current and dutycycle rating of gun.

1. See procedure for replacing P.CBoard.

1. Replace.

1. Check and clean connection. 2. Check table in this manual.3. Set the arc voltage at the rightvalue4. Check and replace if defective. 5. Replace.

18. Variable or sluggish weldingarc

19. Poor arc characteristics

1. Poor work connection.

2. Wire feed speed too fast. 3. Defective contact tip.

1. Control P.C.Board defective

1. Work connection must beadequate for application.2. Adjust correct wire feed speed. 3.Change it.

1. See procedure for replacing P.CBoard.

IM 1044 - WIRING DIAGRAM

- 16 - LN 442

CR02-107

LINCOLN ELECTRIC FRANCEAVENUE FRANKLIN ROOSEVELT

BP 21476121 LE GRAND QUEVILLY CEDEX

TEL : 02 32 11 40 40FAX : 02 32 11 40 11

FAX BUREAU COMMERCIAL : 02 32 11 40 12FAX EXPORT DEPARTMENT : 02 32 11 40 08

FAX SERVICE APRES-VENTES / AFTER SALES DEPARTMENT : 02 32 11 52 08FAX PIECES DETACHEES / SPARE PARTS DEPARTMENT : 02 32 11 40 13