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E-3

TROUBLESHOOTING

E-3

TANDEM MIG TORCH

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility

for technical troubleshooting assistance before you proceed.

CAUTION

PROBLEMS

(SYMPTOMS)

PPOSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Porosity in the weld. (Continued)

The arc length is inconsistent.

There is arcing to the nozzle.

There is arcing between the contact tips
or arc flaring.

g. Wrong shielding gas composition.

h. Lead arc length too short.

i. Water is leaking into the arc.

j. Air is being drafted through the barrel.

k. Weld is too large.

l. Excessive anti-spatter fluid.

m. For installations with an anti-spatter

system, the anti-spatter solenoid may
not be closing completely.

n. For installations without an anti-spat-

ter system, the line may not be
plugged.

a. The contact tip is worn.

b. The liner and/or conduit are dirty or

worn.

c. The drive rolls and guide tubes on the

wire feeder are not properly assem-
bled.

d. The variation in the joint is too large.

e. The electrode or work lead connec-

tions are loose.

f. Only one ground lead is being used.

g. The wrong weld program has been

selected.

a. Spatter build-up is bridging between

the nozzle and contact tips or diffusers

b. The nozzle is too narrow for the appli-

cation.

c. The torch is not insulated from the fix-

ture.

a. Spatter build-up is creating a bridge

between the contact tips.

b. The wire size selection is wrong.

g. Make sure the shielding gas is appro-

priate for the weld procedure.

h. The lead arc should be in the spray or

pulse mode and not in globular or
short arc transfer.

i. Verify that nozzle to torch o-rings are

sealing properly.

j. Check that the o-rings to seal the bar-

rel to the over molded assembly are
sealing properly.

k. Use a trailing gas shield or a nozzle

that supplies a wider coverage of gas
shielding.

l. Use only a minimal amount of anti-

spatter fluid.

m. Verify that the solenoid closes com-

pletely.

n. Make sure the anti-spatter line is

plugged and sealed.

a. The wire should slide freely through

the contact tip. Replace if necessary.

b. Clean the liners and conduit. Replace

if necessary.

c. Make sure the correct size drive rolls

and guide tubes are in the feeder the
wire feeds through without distortion.

d. Improve fixturing and part forming if

necessary, or add seam tracking.

e. Verify that all the connections are tight

and are not overheating.

f. Use an individual ground lead from the

work stud of each power source to the
fixture.

g. Make sure the welding program on the

power source matches the wire size
and gas actually being run.

a. Remove spatter build-up on a regular

basis. Adjust weld procedure to
reduce spatter.

b. Switch to a wider nozzle.

c. Make sure the torch is on an insulated

mount. Use M19190 insulator if neces-
sary.

a. Remove spatter build-up on a regular

basis. Adjust procedure to reduce
spatter.

b. Switch to a larger diameter lead and

trail wire.

Содержание TANDEM IM666-A

Страница 1: ...art DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful G3494 2 3 4 5 6 G3494 2A 3A 4A 5A 6A Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leade...

Страница 2: ...R WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availa...

Страница 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 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 ...

Страница 4: ...event 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 adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 Weldin...

Страница 5: ...propriés et non inflammables 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 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 6...

Страница 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...

Страница 7: ... B 1 Avoiding Wire Feeding Problems B 1 Shielding Gas Delivery B 1 Air Blast Cleaning B 1 Nozzle Reaming Stations B 1 Anti Spatter Spray B 1 ________________________________________________________________________________ Accessories Section C General Options Accessories C 1 ________________________________________________________________________ Maintenance Section D Safety Precautions D 1 Mainte...

Страница 8: ...ility Shielding Gas Flow Rate Water Cooling Flow Rate for each Power Cable HEIGHT WIDTH DEPTH WEIGHT 17 54 in 3 75 in 4 5 in w o bracket 14 0 lbs w 4 ft cable 445 5 mm 95 3 mm 114 3 mm w o bracket 6 4 kg w 4 ft cable PHYSICAL DIMENSIONS 45 gal min at 40 psi 1700 ml min at 2 7 bar Water cooling flow rate for nozzle gas cable 0 035 to 5 64 0 9 mm to 1 9 mm Lead Electrode size 0 035 to 5 64 0 9 mm to...

Страница 9: ...ast Mate adapter kit see ACCESSORIES section to attach the torch to the feeders A K1500 1 gun connector must be installed in addition to the K489 7 Fast Mate adapter when using a Power Feed 10R Wire Feeder Liners are not included with the torch and must be ordered separately see ACCESSORIES section The torch is suitable for welding with Lincoln solid wire steel MIG wires and metal core electrodes ...

Страница 10: ...ndard or tapered contact tips should only be considered in special applications operating at low power Use only Tandem MIG diffusers with the Tandem MIG torch see ACCESSORIES section The Tandem MIG diffusers feature a narrow profile that prevents internal short circuits All of the gas nozzles see ACCESSORIES section also feature internal water cooling to assure a long life of the torch and nozzle ...

Страница 11: ...the nozzle onto the torch and secure it into position with the threaded collar CONNECTING THE TORCH TO THE WELDING EQUIPMENT See Figure 2 There are three cable bundles for the Tandem MIG torch a G3494 X Series Two of the cable assemblies supply power wire and water cooling to each side of the torch The third bundle is made up of the nozzle water cooling hoses the air blast line and the shielding g...

Страница 12: ... 50 100 psi Water Cooling Equipment FIGURE 3 WATER COOLING EQUIPMENT See Figure 3 The Tandem MIG torch requires three separate water coolers for proper cooling of the torch The lead and trail part of the torch each require a water cooler as well as a third cooler for the nozzle The three coolers maintain proper temperatures in the torch even at maximum rated output and duty cycle leading to long p...

Страница 13: ...ex and do not get tangled or caught on other equipment Do not let the cables drag on moving or hot parts Use a collision sensor if there is a risk that the torch may impact an object when the torch or work piece moves The case of the torch has holes drilled on the back left and right sides for mounting the insulator on either the back or side of the torch All of the holes are drilled and tapped fo...

Страница 14: ...d to the welding fixture Do not tightly bundle the electrode leads or the work leads together Welding performance may deteriorate SEAM TRACKING Seam tracking is required if the joint position wanders or varies from part to part Most optical and mechani cal trackers are compatible with Tandem MIG Check the manufacturer s specifications for the seam track ing equipment Do not exceed the rated power ...

Страница 15: ...GAS DELIVERY Adjust flow regulators for prescribed gas flow Inspect hoses regularly for worn or torn hoses Perform a soapy water test on hoses if a leak is suspected Avoid kinking or collapsing hoses with cable clamps Insure that dif fuser is properly seated and tight For G3494 XA series torch two gas sources are required Do not attempt to Y or Tee gas from one flow meter or regulator AIR BLAST CL...

Страница 16: ...mm KP2021 2B1 045 1 2mm KP2021 3B1 052 1 3mm KP2021 4B1 1 16 1 6mm KP2021 5B1 5 64 2 0mm Gas Nozzles S24198 1 1 1 2 x 3 4 37mm x 19mm contact tips recessed 1 8 3mm S24198 2 1 1 2 x 3 4 37mm x 19mm contact tips extended 1 8 3mm S24198 3 1 1 2 x 7 8 37mm x 22mm contact tips recessed 1 8 3mm S24198 4 1 1 2 x 3 4 37mm x 19mm 15 bevel S24198 5 1 5 8 x 1 42mm x 24mm for reamers S24198 6 1 5 8 x 1 42mm x...

Страница 17: ...sembled correctly the face of the torch shield will be flush with the end of the barrel h Assembly of the remainder of the torch is the reverse of the earlier steps FIGURE 5 Torch Shield Replacement TANDEM MIG TORCH SAFETY PRECAUTIONS Have qualified personnel do the maintenance work If a problem cannot be corrected by following the instructions take the equipment to the nearest Lincoln Field Servi...

Страница 18: ...eplace ment schedule should be established and adhered to For general operations contact tips should be changed at the beginning of every shift LINER REPLACEMENT Wire condition and plant environment as well as wire consumption rate dictate how often a liner should be changed Smaller wire diameter will require a more frequent change interval than large diameter opera tions For general operations us...

Страница 19: ...IBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Autho...

Страница 20: ...oating c The arc length is excessively long d Insufficient shielding gas flow e Gas solenoid not turning on f Loose shielding gas connections a Keep as straight as possible Inspect cable and replace if necessary b Remove wire from gun and cable then feed in new wire Check for any obstructions Replace the liner if nec essary c Be sure the wire diameter being used matches the sizes of the drive roll...

Страница 21: ...ch is not insulated from the fix ture a Spatter build up is creating a bridge between the contact tips b The wire size selection is wrong g Make sure the shielding gas is appro priate for the weld procedure h The lead arc should be in the spray or pulse mode and not in globular or short arc transfer i Verify that nozzle to torch o rings are sealing properly j Check that the o rings to seal the bar...

Страница 22: ...NOTES TANDEM MIG TORCH ...

Страница 23: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Страница 24: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Страница 25: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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