How to diagnose Bad Ass Remotes Dual Dial Remote Control for Lincoln Electric Welding Machines

We manufacture the toughest welding remotes in the industry but welding in harsh conditions means the inevitable remote failure. Fortunately with a few easy steps we can pinpoint and repair our remotes in the field fast to get you back to work.

Welding in harsh conditions means the inevitable a remote failure. Fortunately with a few easy steps we can pinpoint and repair most remotes without sending them back in. Read through directions below completely before starting to test remote. Follow the directions step by step. Do not skip over portions of directions below.

 

 

When planning to test remote cable or remote wiring, you will need a volt meter with resistance capability.

 

Turn digital multimeter dial to resistance, or ohms, which often shares a spot on the dial with one or more other test/measurement modes (continuity, capacitance or diode; see illustration below).

  • The display should show OLΩ because, in Resistance mode, even before test leads are connected to a component, a digital multimeter automatically begins taking a resistance measurement.

  • The MΩ symbol may appear in the display because the resistance of open (unattached) test leads is very high.

  • When the leads are connected to a component, a digital multimeter automatically uses the Autorange mode to adjust to the best range.

  • Pressing the Range button allows a technician to manually set the range.

  • Best results will be achieved if the component to be tested is removed from the circuit. If the component is left in the circuit, the readings could be affected by other components in parallel with the component to be tested.

 

1. First insert the black test lead into the COM jack. 2. Then insert the red lead into the VΩ jack.

  • When finished, remove the leads in reverse order: red first, then black.

3. Connect test leads across the component being tested.

  • Make sure that contact between the test leads and circuit is good

 

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To test a Lincoln 6 Pin single dial remote,

  1. Turn off welding machine

  2. Remove remote from cable.

  3. Remove 6 pin connector from welding machine.

  4. Set volt meter to ohms.

  5. Connect volt meter red wire to pin A. , Connect volt meter black wire to number 6 on quick connector. Volt meter should zero. If volt meter says OL the circuit is open.

  6. Connect volt meter red wire to pin B. , Connect volt meter black wire to number 5. on quick connector. Volt meter should zero. If volt meter says OL the circuit is open.

  7. Connect volt meter red wire to pin C. , Connect volt meter black wire to number 4 on quick connector. Volt meter should zero. If volt meter says OL the circuit is open.

If the 110 volt side stops working.

  1. Turn off welding machine.

  2. Remove remote from cable.

  3. Unhook 110 plug from welding machine.

  4. Set volt meter to ohms.

  5. Connect volt meter red wire to Pin 1 of quick connector, and connect black wire to Gold lug of 110 male plug. If volt meter says OL the circuit is open.

  6. Connect volt meter red wire to Pin 3 of quick connector, and connect black wire to Silver lug of 110 male plug. If volt meter says OL the circuit is open.

  7. Connect volt meter red wire to Pin 2 of quick connector, and connect black wire to U shaped lug of 110 male plug. If volt meter says OL the circuit is open.

When doing this test we are checking the most common issue with remotes, wires came unplugged inside quick connector at end of cable.

If any of the wires show a open condition loosen the 4 screws inside the quick connector at the end of the cable, The screws do not come all the way out of quick connector, Push the wire through the quick connector and inspect all wire connections at the quick connector.

If all the wires are connected still but a open condition is found in previous steps, push wire through cable strain relief and quick connector shell approximately 2 feet, cut wire and re attach wires to quick connector. Retest wire.

If the wire now shows resistance or continuity through all pins shown in diagram above, reconnect remote to machine and test remote by welding.

 

 

Remote still does not work.

How to test potentiometer of remote after testing wiring.

  1. Turn off welding machine.

  2. Unhook 6 pin connector from welding machine.

  3. Turn on volt meter and set to ohms.

  4. Turn Low end set point knob to zero, Top knob.

  5. Connect the red voltmeter to Pin A of 6 pin connector, connect black wire to pin C of 6 pin connector, Resistance should be 10K plus or negative 10%.

  6. Turn the top knob to max and bottom knob to zero, connect red voltmeter wire to pin B and connect black volt meter wire to Pin C of 6 pin connector, Resistance should be 10K plus or negative 10%.

  7. Turn bottom knob to max, With red wire still connected to Pin B of 6 pin connector and Black wire still connected to Pin C of 6 pin connector, turn top knob to max, resistance should raise to 20k.

  8. If potentiometer tests do not work, removed the 4 screws on the back of remote box, unhook blue wire coming from bottom potentiometer, unhook blue wire from top potentiometer going back to remote quick connector, connect blue wire from bottom potentiometer to quick connector blue wire. Retest functionality with Single Dial remote testing procedure. If remote fails disconnect bottom potentiometer wires from quick connector inside remote, connect red, orange and blue wires on top potentiometer to remote quick connector wiring inside box. Red to Red, Orange to Orange, Blue to Blue. These final two steps confirm if the top potentiometer needs replaced, or if the bottom potentiometer needs replaced. If remote passes test plug remote into machine and continue welding and replace bad potentiometer.

 

 

When testing remotes follow step by step directions in order.

Do not test remotes with remote connected to welding machine, or machine running.

 

The most common issues with remotes are.

1. Quick connector wiring pulled out of quick connector.

2. Cut wiring inside remote cable.

3. Bad Potentiometer.

4. Your helper doesn't have enough strength to pull remote off metal surfaces.

 

If after following directions you still have trouble with your remote, or you need help always feel free to contact us at 913-952-7743 we are more then willing to help you with any issues or questions.


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