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Lincoln Electric IM849 User's Manual

1. 11 B 11 Memory Panel Description B 12 DEIER B 13 see Section C General Options Accessories C 1 Lusto Section D 9 D 1 Foi IM c E a u ask D 1 EE eee ces tak westside ake Seed aaa St ane ee age D 1 Calibration Specifications D 1 Troubleshooting sense Section E Safety ee TEE 1 How to Use Troubleshooting Guide E 1 Troubleshooting Gude EE E 2 thru 6 Wiring Diagram and Dimension Print ses Section F _ _ 6 P 506 A 1 GENERAL INFORMATION TECHNICAL SPECIFICATIONS POWER FEED 10A CONTROLLER SPEC TYPE 142 1 SPEED RATIO 95 1 SPEED RATIO Wire Size Wire Size POWER FEED 10A CONTROLLER Speed Solid Cored Speed Solid Cored with Power Feed 105 K2362 1 10 200 IPM 7 32 in 5 32 in 10 300 ipm 1 8 in 5 32 in 0 25 5 08 m min 5 6 mm 4 0 mm 0 25 7 62 m min 3 2 mm 4 0 mm TEMPERATURE RATING Storage 40 F to 185 F 40 to 85 Operating 4 F to 104 20 to 40 PHYSICAL SIZE Depth 4 0 in 102 mm Dimensions Width 13 0 in INPUT VOLTAGE amp CURRENT Input Amps 1 0 Model K2362 1
2. NOTE TRAVEL AUTO and TRAVEL ON should not be closed at the same time Either one OR the other should be closed at any time and must remain closed to keep particular Travel Mode active If neither switch is closed at any time travel will be turned OFF regardless of the welding state Inching and Flux switches will activate their particular function when the switch is closed and will cease when opened The START and STOP switches are MOMENTARY and only need to be closed for a short period of time to start or stop the weld sequence 6 Any custom or non Lincoln equipment can be pow ered by the normally open contacts from relays CR1 CR2 or CR3 The normally open contacts for CR1 are located on terminal strip blocks 5 and 6 The normally open contacts for CR2 are located on terminal strip blocks 12 and 13 The normally open contacts for CR3 are located on terminal strip blocks 19 and 420 CR1 and CR2 are BOTH turned ON when the weld sequence starts and are BOTH turned OFF when the weld sequence stops as long as the TRAVEL MODE Switch is in the AUTO position The input supply voltage to power these devices is provided by the end user As shipped the PF 10A has the auxiliary supply blocks terminal strip blocks 48 and 49 connected to the CR2 relay and CR3 relay inputs respectively When the end user con nects a supply to the AUX blocks 48 and 49 this voltage will be jumpered to the CR2 and CR3 relay inputs on
3. A 2 High Frequency Protection sr A 2 Auxiliary Equipment Input Power A 2 Interfacing to the POWER FEED 10A CONTROLLER A 3 thru A 4 Controling Non Lincoln Auxilliary Equipment seen A 5 thru A 6 Connection Diagram System A A 7 Remote Sense Lead Specifications A 8 V Section B Safety 8 1 Design ad 8 1 Definitions of Welding Modes 8 1 Common Welding Abbreviations 12 eann ete B 1 Pred etiDeSeriptioni QL 5 B 2 Recommended Processes siens B 2 Locating Front Panel Controls and Input Output Connections B 3 Case Front Controls and Description B 4 thru B5 Power Up Sequence B 5 Inch Wire Feed Speed Settings AAA B 5 Ghanging Weld L assqa 8 6 Mode Select Pariel 4 MSP4 S 09 5 5 56 8 6 Weld Mode DescgrIDIIOn 8 6 7 a aa aar aaa a E A N e e a a EECa B 7 End cierna E B 8 Weld Sequence Parameter List nennen B 9 General Setup Mode Options B 10 Infrared IR Oonllol
4. Arc Display Mode Press the right Mode Select Button Turn the Knob to toggle between Amps or WFS The POWER FEED 10A CONTROLLER can start and stop travel based on the START and STOP Pushbuttons or based on the arc being established or extinguished To access the Travel Options in the Setup Mode enter into the Setup Mode by pressing both Mode Select Panel Pushbuttons simultaneously The SETUP LED will illuminate Turn the Mode Select Panel Knob until TRAVEL OPTIONS is listed Travel Options P 12 SETUP POWER FEED 10A CONTROLLER LINCOLN P Here is a list of Lockout levels PANEL LOCKOUT LEVEL All Mode Select options unlocked default All Mode Select options locked START OPTIONS and END OPTIONS locked WELD MODE selection locked only wave controls are unlocked useful when Memory Mode Select Panel is used to recall weld modes AC CONTROL locked START OPTIONS END OPTIONS and wave options locked START OPTIONS END OPTIONS and WELD MODE locked All memories enabled default All memories disabled Memories 2 6 disabled Memory Panel Memories 3 6 disabled Memories 4 6 disabled Memories 5 6 disabled Memory 6 disabled Both knobs unlocked default Both knobs locked Encoder Panel Right knob locked Left knob locked Note that when an option is locked its value can still be monitored For example if start and end options are locked the welder can still press the
5. CAUTION 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 POWER FEED 10A CONTROLLER LINCOLN 5 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION LINC NET SYSTEM ERROR CODES The wire feeder has not received a recognition command from the power source Verify the power Source is operating properly Status light steady green Check control cable for loose or broken leads See power source Instruction Manual The power source has issued a shutdown command Verify the power source is operating proper ly Status light steady green Check control cable for loose or broken leads See power source instruction Manual If all recommended possible areas of misadjustment have been checked ARCLINK SYSTEM ERROR CODES and the problem persists Contact Primary overcurrent The power source has exceeded your local Lincoln Authorized input current limits Adjust the Field Service Facility welding procedure to reduce the current draw The welding proce dure may exceed the capacity of the power source See the power source Instruction Manual Err 32 Capacitor bank A under 1 The power source input power voltage
6. Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 5 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CG
7. VA ai Un Ai Y Bac jaa daag Age Ai dl A aad A AA ui 289 se aad Q LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR GK lt EE gt k lt MRA 4898 CL TRHOKRSMEI HIT FEU BA 5 9 N FE PF S 15 1 9 ER BB bl R 6 5 FR 36 EB 8 ST M 55 1 712 0 AZo SSE ali FA AUX CSAS ESA HHC ve kel Z dl aui y A3 gial LINCOLN World s Leader in Welding and Cutting Products 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
8. The POWER FEED 10A CONTROLLER has a Stop Input available on the terminal strip The Stop Input will work just like pressing the STOP Pushbutton This circuit is in parallel with the STOP Pushbutton located on the Switch Panel Unlike the Shutdown Inputs which completely shutdown all welding and auxiliary equipment the STOP Input will allow all welding and auxiliary motion to continue based on the END OPTIONS configurations in the POWER FEED 10A CONTROLLER 1 Remove all input power to the POWER FEED 10A CONTROLLER including any auxiliary power supplies 2 Remove the wire duct cover to gain access to the leads on the right side of the terminal strip 3 Remove one of the plug buttons located on the bot tom of the POWER FEED 10A CONTROLLER control box and install some type of strain relief for the auxiliary control leads 4 Connect the external Stop Input circuit to terminal blocks 28 and 29 The Stop Input is not necessary if the POWER FEED 10A CONTROLLER is configured for Remote Interfacing mentioned earlier due to the fact that the Stop circuit can be accessed in this configuration on terminal strip blocks 39 and 41 The Stop Input was intended to be used when the Switch Panel is still included in the system either on the Controller or in the Pendant Note the STOP circuit only needs a momentary clo sure to be recognized by the POWER FEED 10A CONTROLLER If the STOP button is held the START
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10. 4 Connect the external shutdown circuit to either of the shutdown terminal blocks 24 amp 25 and or 26 8 27 normally closed circuit must be con nected the POWER FEED 10 CONTROLLER will recognize an open circuit as a shutdown com mand 5 Remove the shorting jumpers imbedded in the cen ter of the terminal strip with a small screwdriver for the shutdown circuits to be used When 8 shutdown input is received all welding will stop and an error message will be displayed on the POWER FEED 10A CONTROLLER The shutdown circuit must be closed before resetting Controller To reset the system the Mode Select Panel display will prompt the user to press the left Mode Select Panel Pushbutton POWER FEED 10A CONTROLLER LINCOLN 8 7 INSTALLATION A 7 CONNECTION DIAGRAM SYSTEM POWER WAVE AC DC 1000 K2344 1 POWER FEED 10A CONTROLLER CONTROL BOX K2362 1 CONTROL 3 em Ms g O K1543 XX ARCLINK CONTROL CABLE K1785 xx 14 14 PIN FEEDER CABLE ELECTRODE SENSE LEAD POWER FEED 10SF WIRE DRIVE SUBARC CONTACT K2312 1 NOZZLE K231 xxx WORK P WORK SENSE LEAD POWER FEED 10A CONTROLLER LINCOLN 8 INSTALLATION A 8 REMOTE SENSE LEAD SPECIFICATIONS Welding with Multiple Arcs Special care must be taken when more than one arc is welding simultaneously on a single part Arc blow and arc interference may occur or be m
11. ABLES READ THIS WARNING PROTECT YOURSELF amp OTHERS FUMES AND GASES can be 23 dangerous E 0 Keep your head out of fumes Use ventilation or exhaust at the arc or both to keep fumes and gases from your breathing zone and general area WELDING SPARKS can cause gt fire or explosion lt Do not weld near flammable material lt Do not weld on containers which have held flammable material ARC RAYS can burn 1 Wear eye ear and body protection POWER FEED 10A CONTROLLER LINCOLN P 2 e When the POWER FEED 10 CONTROLLER is coupled to a Power Wave welding power source the result is a welding system with the best arc perfor mance on the market RECOMMENDED PROCESSES POWER FEED 10A CONTROLLER is best suited for submerged arc welding e SAW PROCESS LIMITATIONS MIG processes The Mode Select Panel does not support Spot welding Not all weld modes or processes described in this manual are available on all Power Wave power sources EQUIPMENT LIMITATIONS POWER FEED 10A CONTROLLER does not operate with the Power Wave 450 POWER FEED 10A CONTROLLER does not operate with any analog based power sources CV xxx machines DC xxx machines etc COMMON BASIC EQUIPMENT PACKAGES Basic Packages Power Wave 1000 AC DC Power Feed 10SF Wire Drive Basic Optional Kits Power Feed 10SM Motor Conversion Kit Converts Lincoln NA style
12. SETUP WELD WFS WELD MODE 7 START OPTIONS ARC CONTROL END options SET Attribute POWER FEED 10A CONTROLLER LINCOLN 1 ACCESSORIES 1 K325 TC 3 Travel Carrriage K299 Wire Reel Assembly for 50 60lbs Coils K162 1 Spindle Kit 2in hub K29 Vertical Lift Adjuster K96 Horizontal Adjuster K278 SpreadArc Oscillator K310 Flux Screen Air Driven Vibrator K58 Magnetic Separator GENERAL OPTIONS ACCESSORIES K2311 1 Power Feed 10SM Converts NA style wire drives into Power Feed 10S Wire Drives K2370 1 Power Feed 10S Wire Drive Power Feed 10S with hardware to connect to a TC 3 Travel Carriage K2282 1 System Interface Includes phase generator for multiple arcs K1543 xx ArcLink Cables ArcLink cable of length xx K1842 110 Weld Power Cable Lug to Lug 4 0 Cable of length 1 10ft K2163 xx Weld Power Cable Lug to Lug 4 0 Cable of length xx K1795 xx Power Wave to System Interface Cable K1785 xx Wire Drive Cable K231 x Contact Nozzle Assembly K226R Contact Jaw Assembly K148 Positive Contact Assembly K149 Linc Fill Attachments K386 Narrow Gap Deep Groove Nozzle K285 Concentric Flux Cone Assembly K225 Contact Assemblies K129 Tiny Twinarc Assemblies K281 Tiny Twinarc Solid Wire Straightener POWER FEED 10A CONTROLLER LINCOLN 5 D 1 MAINTENANCE 1 ROUTINE MAINTENANCE Check weld cables
13. 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 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 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 Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation
14. control cables and gas hoses for cuts Clean and tighten all weld terminals Inspect and clean drive rolls and inner wire guide and replace if worn PERIODIC MAINTENANCE Blow out or vacuum the inside of the feeder Every six months check the motor brushes Replace them if they are less than 1 4 6 4mm long Every year inspect the gearbox and coat the gear teeth with a moly disulfide filled grease DO NOT use graphite grease CALIBRATION SPECIFICATION All calibration is factory set on the POWER FEED 10A CONTROLLER To verify the wire feed speed Press the INCH DOWN switch and adjust the wire feed speed to 100 in min 2 54m min Measure the actual wire feed speed with a calibrat ed wire feed speed tachometer The measured wire feed speed should be within 2 of the set value SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal e wiring e When inching electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the inch but ton is released Turn OFF input power at welding power source before installation or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform mainte nance work See additiona
15. Se our ass e jo AE m s Ach W ol ja oui Y 6 pec A A el SCT all dane Y le tg WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR Chinese Korean READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes e Turn power off before servicing Do not operate with panel open or Use ventilation or exhaust to guards off remove fumes from breathing zone WA R N M G Los humos fuera de la zona de res e Desconectar el cable de ali No operar con panel abierto o Spanish piraci n mentaci n de poder de la m quina guardas quitadas AVISO D E e Mantenga la cabeza fuera de los antes de iniciar cualquier servicio humos Utilice ventilaci n o PRECAUC
16. Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 SAFETY Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc
17. and INCH UP comes from SWITCH GROUP 1 SUPPLY on block 439 The supply for TRAVEL AUTO TRAVEL ON FLUX FILL and INCH DOWN comes from SWITCH GROUP 2 SUPPLY on block 43 9 To activate any of the Switch Panel circuits a con tact closure must be established between the sup ply and the particular circuit it is referenced to for instance to start the weld sequence a contact clo sure must be established momentarily between ter minal strip blocks 39 SUPPLY and 40 START See FIGURE A 2 10 The leads from the 14 pin connector that were removed from the terminal strip can be taped and secured in the wire duct located next to the termi nal strip 4 Replace the Switch Panel on the POWER FEED 10A CONTROLLER with the blank panel included with the pendant box 5 Connect the Switch Panel to the mating 10 pin con nector inside the pendant box 6 Fasten the Switch Panel to the pendant box 7 Connect the 14 pin 9 pin pendant cable to the mat ing cable connector on the bottom of the POWER FEED 10A CONTROLLER and the mating cable connector on the pendant 8 The remote pendant is now ready to be used Interfacing to the Switch Panel Controls The Switch Panel circuits can be accessed on the screwless terminal strip Easy access to these circuits enables the POWER FEED 10A CONTROLLER to interface with custom controls or PLC s These circuits must see a contact closure to function properly 1 Remove all input
18. has been developed for this purpose LOCKOUT SECURITY The Power Feed 10A can be optionally configured to prevent the operator from changing selected Power Feed 10A panel controls By default the welder will be able to change the weld mode all relevant wave controls and all relevant start and end options POWER FEED 10A CONTROLLER LINCOLN P B 12 OPERATION B 12 MEMORY PANEL DESCRIPTION MEMORY m m g set limits 10 to clear limits Hold d m After holding the memory button in for two seconds the LED will turn off indicating that the memory will be saved when the button is released When saving a memory do not hold the memory button in for more than five seconds Memory saving can be optionally disabled using Lockout Levels If the user attempts to save a memo ry when memory saving is locked the Mode Select Panel will briefly display Memory Save is DIS ABLED Presently Memory Panel Lockout Levels can only be accessed through a PC application or the IR Port MULTI PROCEDURE WELDING The POWER FEED 10A CONTROLLER can do On The Fly welding with multiple weld procedures by using the Memory Panel While welding any Memory location can be accessed and the parame ters stored in that memory location will be switched to while actively welding NOTE This can only be done with Memory locations that have the same Weld Mode While welding any Memory location try ing to be accessed wi
19. may be wired incorrectly Verify the power source reconnect panel wiring matches the input power See the power source Instruction Manual CAUTION 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 POWER FEED 10A CONTROLLER LINCOLN 5 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION ARCLINK SYSTEM ERROR CODES Capacitor bank B under 1 The power source input power voltage may be wired incorrectly Verify the power source reconnect panel wiring matches the input power See the power source Instruction Manual Capacitor bank A overvolt 1 The power source input power age may be wired incorrectly Verify the power source reconnect panel wiring matches the input power See the power source Instruction Manual Capacitor bank B overvolt 1 The power source input power age may be wired incorrectly Verify the power source reconnect panel wiring matches the recommended possible areas of power misadjustment have been checked and the problem persists Contact See the power source Instruction your local Lincoln Authorized Manual Field Service Facility Thermal Power source overheating Verify d
20. parameter settings and actu al levels while welding 2 ARC ESTABLISH INDICATOR Illuminates when a true arc has been established Flashes when open circuit voltage is applied Not availiable on all units upgrade software to include this feature POWER FEED 10A CONTROLLER LINCOLN P 8 5 OPERATION B 5 11 INCH DOWN Feeds the wire downward toward the work NOTE The Power Feed 10A includes an option in the Setup Menu P 15 to enable the touch sense circuit ry in the power source Having this feature enabled will stop the wire when it comes in contact with the work engaging the flux hopper on contact for automatic flux fill The flux hopper will disengage when the INCH DOWN button is released A WARNING This Hot Inch feature enables the output Avoid touching any exposed parts as defined in the Installation Section A 2 12 MEMORY PANEL Enables the storage and recall of up to 6 weld schedules Enables weld parameter limit setting 13 MODE SELECT PANEL The main user interface for weld mode selection welding parameter adjustment and multiple levels of user lockouts Bright 7 segment display and alphanumeric displays enable text messag ing for user friendly parameter setup POWER UP SEQUENCE When power is first applied to the machine a lamp test is performed All discrete LED s are turned on all 7 segment displays will show a pattern of 8 and all alphanumeric dis plays will show a hatch patt
21. peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET S Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux mach
22. poor work connection Verify all work and electrode connections are tight and that the cables are in good condition Clean replace as nec essary Wrong polarity Adjust polarity to the recommended procedure If all recommended possible areas of Verify DIP switch 7 setting misadjustment have been checked matches the electrode polarity and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION 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 POWER FEED 10A CONTROLLER LINCOLN 5 POWER FEED 10A CONTROLLER LINCOLN E Y 1 quinu epoo 1u uudinb
23. power to the POWER FEED 10A CONTROLLER including any auxiliary power supplies 2 Remove the fasteners from the Switch Panel and disconnect the Switch Panel from the wire harness The Switch Panel should be stored in a secure CAUTION place in the event that it is needed in the future The Switch Panel should not be left in the POWER FEEDTM 10A CONTROLLER if the switches are not connected This could cause a safety concern due to the fact that the switches will not stop the welding sequence etc 3 Jumper the wire harness connector J2 to the mat ing 10 pin connector P2P that is floating inside the control box See Wiring Diagram 4 Replace the Switch Panel on the POWER FEED 10A CONTROLLER with the blank panel included with the pendant box 5 Remove the wire duct cover to gain access to the leads on the right side of the terminal strip 6 Remove the leads going to the Pendant 14 pin con nector from the right side of terminal strip blocks 39 40 41 42 43 44 45 46 amp 47 Note see Auxiliary Input Power Connection Instructions on how to remove install wires to the screwless terminal strip POWER FEED 10A CONTROLLER LINCOLN 5 A 5 INSTALLATION A 5 FIGURE A 2 SWITCH GROUP _ 43 2 SUPPLY 44 TRAVEL AUTO 5 45 TRAVEL ON 46 FLUX FILL 47 INCH DOWN QO 439 SWITCH GROUP 1 SUPPLY 40 START 41 STOP 42 INCH UP
24. should be inserted until it bottoms out This opens the screwless cage clamping style wire insertion port The insulation on the leads should be stripped at least 0 25 6 4mm With the cage clamp opened insert the wire into the round port until it bottoms out While holding the lead securely remove the screwdriver from the terminal block This closes the cage clamp onto the lead holding it securely Any open port on blocks 48 49 and 50 may be used 5 The 4 terminal blocks numbered 48 49 and 50 are to be used to bring in auxiliary power Terminal block 50 is used for the input ground connection This terminal block is color coded green and yellow for easy identification Terminal blocks 48 and 9 are to be used to connect the input power circuit See figure A 1 FIGURE A 1 O 48 NEUTRAL 31 O 49 CI INE 82 50 O O GNDIN GND TY 1 INSERT SCREW 2 DRIVER HERE WIRE HERE 3 REMOVE SCREW DRIVER FROM CAGE CLAMP HOLE CAGE CLAMP POWER FEED 10A CONTROLLER LINCOLN 5 A 4 INSTALLATION 4 7 Remove one of the plug buttons located on the bot tom of the POWER FEED 10A CONTROLLER control box and install some type of strain relief for the interfacing leads 8 Connect the interfacing leads to the Switch Panel circuits on the terminal strip see Wiring Diagram for terminal strip designations The supply for START STOP
25. terminal strip blocks 11 17 and 8 Note the CR1 relay is not connected to the AUX terminal strip blocks the customer must connect power to this relay if it is to be used See relay rat ings listed earlier CONTROLLING NON LINCOLN AUXILIARY EQUIPMENT Custom motion control and or other auxiliary equip ment can be powered using the terminal strip and relays To use non Lincoln motion control and or flux hoppers follow instructions below 1 Remove all input power to the POWER FEED 10A CONTROLLER including any auxiliary power supplies 2 Remove the wire duct cover to gain access to the leads on the right side of the terminal strip 3 Remove one of the plug buttons located on the bot tom of the POWER FEED 10A CONTROLLER control box and install some type of strain relief for the auxiliary control leads 4 Remove the leads going from the terminal strip to the corresponding connectors i e terminal strip blocks 11 13 and 16 for the 4 pin TC 3 Travel Carriage or terminal strip blocks 19 20 and 3 for the 3 pin Automatic Flux Hopper 5 These loose leads can be taped and secured in the wire duct POWER FEED 10A CONTROLLER LINCOLN 8 A 6 INSTALLATION A 6 Shutdown 2 can be configured for Output Lockout mode by enabling option P 21 in the Setup Menu Refer to Section B General Setup Mode Options when the input is opened output is disabled but cold feed of wire is still possible Stop Input
26. 259 mm When not driving a motor WELDING PROCESSES Output Range Wire Feed Speed Range Amperes 1000 Amps Electrode Diameter Range 5 64 in 7 32 in 2 0 5 6 mm Process 10 300 ipm 0 254 7 62 m minute SAW POWER FEED 10A CONTROLLER LINCOLN 8 HIGH FREQUENCY PROTECTION Locate the POWER FEED 10A CONTROLLER away from radio controlled machinery The normal operation of the POWER FEED 10A CONTROLLER may adversely affect the operation of RF controlled equipment which may result in bodily injury or damage to the equipment AUXILIARY EQUIPMENT INPUT POWER CON NECTION The POWER FEED 10A CONTROLLER has the ability to control auxiliary equipment such as flux hoppers and travel motors using solid state relays There are three relays in the POWER FEED 10A CONTROLLER controlled by two independent coil drivers The coils of CR1 and CR2 are in parallel therefore they must turn ON and OFF at the same time The CR1 and CR2 relays are designated for driving travel motors to control motion CR3 is driven separately and is designated to control flux hopper operation POWER FEED 10A CONTROLLER Relay Ratings Coil 12 06 resistance 86 ohms at 25 C N C Contacts 60 6 N O Contacts 30A 277Vac POWER FEED 10 CONTROLLER does not provide the input power to feed auxiliary equipment therefore a sep arate power feed must be provided by the end user T
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28. A publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Jan 09 SAFETY WELDING and CUTTING gt SPARKS cause fire or explosion 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 adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 When not welding make certain no part of the electrode circuit is touching the work or ground Accide
29. E IS IT SET FF MSP4 START OPTIONS MSP4 SETUP Menu Weld WFS Amps IPM amperes from weld table weld mode dependant Left Dual Display Weld Volts from weld table weld mode dependant Right Dual Display F 1 F Arc 2 Phase if applicable 0 359 AC CONTROL Arc 2 Balance if applicable 25 75 5 AC CONTROL Arc 3 Phase if applicable 0 359 180 AC CONTROL Arc 3 Balance if applicable 25 75 5 AC CONTROL 70 F F Arc 4 Phase if applicable 0 359 2 AC CONTROL Arc 4 Balance if applicable 25 75 5 AC CONTROL Downslope Time 0 10 0 0 MSP4 SETUP Menu F Crater WFS Amps IPM amperes from weld table weld mode dependant Left Dual Display F 0 0 0 Crater Volts from weld table weld mode dependant Right Dual Display Crater Arc Force from weld table weld mode dependant MSP4 SETUP Menu Burnback Time 0 2 END OPTIONS Range depends on the Machine Power Source Literature and Tables supplied with each unit POWER FEED 10A CONTROLLER LINCOLN B 10 Pressing the right Mode Select Panel Pushbutton will enter into the Travel Options Turning the Mode Select Panel Knob will toggle between TRAVEL STARTS and TRAVEL STOPS Pressing the right Mode Select Panel Pushbutton will allow the travel to be set to start on the START BUTTON or on the ARC STRIKE and to stop on the STOP BUTTON or on the ARC OUT P 12 Start Button SETUP Travel Starts OPERATION B 10 GENERAL SETUP MODE OPTIONS The Setu
30. EED 10A CONTROLLER The POWER FEED 10A CONTROLLER is a versa tile controller The Switch Panel can be removed and made into a hand held pendant Most circuits can be accessed through the screwless terminal strip The auxiliary relays can control standard Lincoln equip ment or they can be used to control any other auxil iary equipment see relay rating information above Custom controls or PLC interfacing to control starting stopping motion etc can be accomplished with ease Converting Switch Panel to a remote pendant 1 Remove all input power to the POWER FEED 10A CONTROLLER including any auxiliary power supplies 2 Remove the fasteners from the Switch Panel and disconnect the Switch Panel from the wire harness 3 Jumper the wire harness connector J2 to the mat ing 10 pin connector P2P that is floating inside the control box See Wiring Diagram INSTALLATION A 3 Auxiliary Input Power Connection Instructions 1 Remove two Phillips Head screws on right side of front panel of hinged door to access terminal strip 2 Remove a plug button and install a box connector to provide strain relief for the input power leads 3 Use the appropriate size leads at least 14 AWG 2 wire with ground 4 Using a flat head screwdriver with a blade dimen sion of 0 137 3 5mm x 0 020 51mm insert the screwdriver into the square hole next to the mount ing hole to be used on the terminal strip The screwdriver
31. ION aspiraci n para gases Gardez la t te l cart des fum es D branchez le courant avant l entre e N op rez pas avec les panneaux French Utilisez un ventilateur ou un aspira tien ouverts ou avec les dispositifs de teur pour ter les fum es des zones protection enlev s ATTE NTI ON de travail e Vermeiden Sie das Einatmen von 6 Strom vor Wartungsarheiten e Anlage nie ohne Schutzgeh use German Schweibrauch abschalten Netzstrom v llig ff oder Innenschutzverkleidung in e Sorgen Sie f r gute Be und nen Maschine anhalten Betrieb setzen WA R N U NG Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a Nao opere com as tampas removidas e Mantenha se afastado das partes Portuguese Use ventilac o e exhaust o para e Desligue a corrente antes de fazer moventes A remover fumo da zona respirat ria servico Nao opere com os paineis abertos ATE NCAO e Nao toque as partes el tricas nuas guardas removidas enzwsens kmRunurzz 22 2 2955 61256 Fe 94905 LEU TFA omm I I o HENNE XXIII MAAS 58786 Chinese e EU e H3244 SH7IAS Waje e tpn AAS pol ya Ae 5 e 522 15 5 ORY HAPI AH 2129214 27 amp HSHM OAA Je dul 6 a AY i Jd t JN Aye
32. June 2009 POWER FEED 1 CONTROLLER For use with machines having Code Numbers 9 IP 21S LI NCOLN Copyright Lincoln Global Inc 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 thought ful operation on your part 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 carelul OPERATOR S MANUAL World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and u
33. MODE will illuminate the AC CONTROL LED if AC parameters are available Repeated pressing of the Left Mode Select Panel Pushbutton will scroll through the available parameters The Mode Select Panel 7 segment display will show the current setting for the parameter and the lower alphanumeric display and will display the name of the parameter Turning the Mode Select Panel Knob will change the setting The frequency range will be 10 Hz to 100 Hz The balance limits will be 25 to 75 The OFFSET limits will be 50 to 45096 The parameters that can be set by the user in the AC OPTIONS will be as fol lows FREQUENCY MSP4 BALANCE MSP4 OFFSET MSP4 ARC 2 PHASE MSP4 ARC 2 BALANCE MSP4 ARC 3 PHASE MSP4 ARC 3 BALANCE MSP4 ARC 4 PHASE MSP4 ARC 4 BALANCE MSP4 The AC CONTROL parameters can be set to READ ONLY requiring a passcode to be entered in order to change any of the settings Presently this can only be done with a Palm or PC application POWER FEED 10A CONTROLLER LINCOLN B 8 OPERATION B 8 P 11 w SETUP RESTRIKE TIME MSP4 seconds Turning the Mode Select Panel Knob will toggle through all user preferences and factory set welding parameters The lower alphanumeric display will read Yes prompting the user to press the right Pushbutton to enter into the chosen parameter set if available Once the parameter set has been selected turning the Mode Select Panel Knob will toggle through the paramet
34. a zi 13M9I O et O sano ee E W 1 T 3DVLdD3H O si O am I Ste Sg Nid 8 2H O vi O au eme 1 Y 9 oNzuo C ezuo 3 0LIX 14 a E 0 C SUR 305 3 NOWNOO C IL O zuo Se 7 AAA aws 90 0V O or O zuo a UH cm E O 6 O vanos So 4 5 5 8 5808 NYO 6 A A A A A A aus v MOISSNA NYO L ON O 8 O swa e on tuo O 2 O eio Si E puis n 9 O 9 O 9189 4 1 sen Soe 1 Lee O s O sn Sr Si RTE ema O 89 D i 08 99 gt z gt gt O 5 O rio gt olzlo quvoa 31099 Ad 9I915 1TVNIWH3L F 2 M20414 F 2 DIMENSION PRINT WARNING z 0c9v5 G4620 3 O POWER FEED 10A CONTROLLER LINCOLN Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot
35. agnified Each power source requires a work lead from the work stud to the welding fixture Do not combine all of the work leads into one lead Perform welding in the direction away from the work leads Connect all of the work sense leads from each power source to the work piece at the end of the weld such that they are out of the path of the weld current For the best results when pulse welding set the wire size and wire feed speed the same for all the arcs When these parameters are identical the pulsing fre quency will be the same helping to stabilize the arcs CONNECT ALL SENSE LEADS AT THE END N OF THE WELD DIRECTIO OF Ee CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD POWER FEED 10A CONTROLLER LINCOLN 8 DESIGN FEATURES Mode Select Panel for easy control of all weld para meters Memory Panel for easy storage and recall of weld schedules Weld parameter limit setting and lockout capabilities Digital communications for accurate and reliable per formance Infrared red IR port for transferring weld settings PC boards are potted in epoxy for the ultimate in out door protection Connectors are filled with environmental protective grease Designed for the Power Wave series of products for the best arc in the industry Wire feed speed accuracy calibrated to within 2 Digital display of voltage and wire feed speed Tachometer controlled wire drive motor Fl
36. and INCH buttons are not recognized 8 Connect input supply voltage per the Auxiliary Input Power Connection Instructions listed earlier 9 The relays could also be used to provide contact closure for any interfacing signals out using the nor mally open contacts An external auxiliary supply voltage would not be necessary to use the relays as hard contact closure out signals NOTE The CR1 relay as shipped does not have AUX leads connect ed to it This relay has two normally open contacts that close at the start of the weld cycle and open at the end of the weld cycle These hard contact clo sures could be used as a signal out when interfac ing to PLC s or custom controls Shutdown Inputs The POWER FEED 10A CONTROLLER has two shutdown inputs available on the terminal strip These are independent normally closed inputs that can be used for limit switches PLC inputs etc in order to shut down the welding operation for any reason Shutdown 1 is located on terminal strip blocks 4 and 425 Shutdown 2 is located on terminal strip blocks 26 and 27 1 Remove all input power to the POWER FEED 10A CONTROLLER including any auxiliary power supplies 2 Remove the wire duct cover to gain access to the leads on the right side of the terminal strip 3 Remove one of the plug buttons located on the bot tom of the POWER FEED 10A CONTROLLER control box and install some type of strain relief for the auxiliary control leads
37. d 49 are shipped connected to CR2 and CR3 532 and 531 leads and these relays are connected to the 3 pin and 4 pin connectors locat ed on the bottom of the POWER FEED 10A CON TROLLER CR is available for a separate customer connection but it will turn ON and OFF with CR2 Therefore if Lincoln auxiliary equipment is to be used connecting 115Vac to the terminal strip is all that is required to power the devices NOTE The contacts of CR1 are not connected to ter minals 48 and 49 when shipped Applying power the 48 and 49 terminals will not transfer voltage to the CR1 relay Connect leads from the 48 terminal to the 4 terminal and from the 49 terminal to the 3 terminal to supply power to the common contacts of the relay Once input power is applied to the terminal strip this voltage is always on terminal strip blocks 3 4 if connected 11 17 and 18 These are the inputs to the solid state relay contacts Input voltage is also present on terminal strip blocks 7 8 if connected 15 21 and 22 due to the N C contacts on the relays When the relay is energized input power is transferred to terminal strip blocks 5 and 6 if connected When the CR2 relay is energized input power is transferred to terminal strip block 13 When the CR3 relay is energized input power is transferred to terminal strip blocks 419 and 20 CR1 and CR2 will be turned ON and OFF at the same time INTERFACING TO THE POWER F
38. de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes LINCOLN 8 v v for selecting a QUALITY product by Lincoln Electric We want you Tha You to take pride in operating this Lincoln Electric Company product ses as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses Sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any res
39. ding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving gt Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your bogy 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to t
40. eep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 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 spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 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 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 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 Also see item 1 b Jan 09 5 f ELECTRIC SHOCK can kill 3 8
41. en checked and the problem persists Contact your local Lincoln Wait for the error to reset and the Authorized Field Service Facility motor to cool approximately 1 minute being used Err82 Motor overload short term The wire drive motor current draw has exceeded limits usually because the motor is in a locked rotor state Check that motor can turn freely when idle arm is open Verify that the gears are free of debris and dirt Err 263 No usable weld modes The power source does not have any welding programs loaded See the power source Instruction Manual for load welding pro grams CAUTION 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 POWER FEED 10A CONTROLLER LINCOLN 5 E 5 TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS The feeder does power up no dis 1 The Power Wave power source is play no feed OFF Turn ON the Power Wave Source The circuit breaker for the wire feeder on power source has tripped Reset the circuit break ers The control cable may be loose or damaged Tighten repair or replace the control cable The power switch is damaged Replace the power switch Inconsistent wire feeding or wire not 1 The electrode is r
42. ern where every other pixel is illuminated The lamp test will last for two seconds after which all displays are turned back off The 16 character alphanumeric display will show Initializing while waiting for the Weld Sequencer to configure The Mode Select Panel alphanumeric displays will then display the name of the weld table loaded in the attached power source while the user interface prepares the machine for operation After all initialization is complete the Mode Select Panel will dis play the weld mode information for the mode number that was selected when the machine was last powered down WIRE FEEDER SETUP Use the INCH UP INCH DOWN pushbottons to insert wire into feed mechanism Prior to inserting the wire make sure the Touch Sense option is disabled P 15 in the Setup Menu INCH WIRE FEED SPEED SETTING While pressing either the Inch Up Pushbutton or the Inch Down Pushbutton the preset wire feed speed will be dis played on the Dual Display panel This value can be changed while inching wire by turning the WFS Encoder and will be stored into memory Occurs during a reset and indi cates the power source is identify ing each component in the system This is normal for the first 10 sec onds after power up or if the sys tem configuration is changed dur ing operation Blinking green Non recoverable system fault If the power source or wire feeder status LED is flashing any combi nation of red and green er
43. ers available in the selected set while show ing the current setting for each parameter in the 7 segment display The parameters will blink in the Mode Select Panel lower alphanumeric display prompting the user to press the right Mode Select Panel Pushbutton to select the parameter Once the parameter has been selected the lower Mode Select Panel alphanumeric display will no longer blink the parameter and the current setting of the parameter will blink in the Mode Select Panel 7 segment display prompting the user to change the setting Pressing the left Mode Select Panel Pushbutton will exit the para meter setting section returning to the previous sec tion Continuing to press the left Mode Select Panel Pushbutton will return to the Setup Mode user prefer ences and welding parameters list 0 3 Seconds SETUP Downslpe Time END OPTIONS Pressing the Right Mode Select Panel Pushbutton after scrolling through the Start Options will illuminate the END OPTIONS LED Repeated pressing of the Right Mode Select Panel Pushbutton will toggle through the parameters Turning the Mode Select Panel Knob while on a parameter will change its value When the Crater Time is set to a value other than OFF the END OPTIONS LED will blink synchro nous with the WFS or Amps LED depending on CC or CV Weld Modes and with the Volts LED located on the Dual Display Panel prompting the user to enter these parameters The parameters that can be set by t
44. ettings arc starting parame ters arc end parameters and set up information The Memory Panel allows for up to six weld sched ules to be stored and quickly recalled The Memory Panel along with the Mode Select Panel allows for multiple levels of limits and lockouts Digital communications to the power source provide the most accurate and reliable operation possible POWER FEED 10 CONTROLLER is one of the first user interfaces with an infrared red IR port Transferring weld settings from one user interface to another is accomplished with a common Palm com puter POWER FEED 10A CONTROLLER LINCOLN P B 3 OPERATION B 3 LOCATING FRONT PANEL CONTROLS AND INPUT OUPUT CONNECTIONS 14 PIN CONTROL BOX WITH DOOR 4 PIN TRAVEL RECEPTACLE 3 PIN FLUX RECEPTACLE 5 PIN INPUT RECEPTACLE Q O CS CONTROL BOX lt WITHOUT DOOR POWER FEED 10A CONTROLLER LINCOLN P 52 OPERATION 4 CASE FRONT CONTROLS WARNING gt VOLTS TRIM LINCOLN V 3 Status LED The status LED indicates system sta tus Normal operation is a steady green light Note During normal power up the LED may flash red and or green as the equipment performs self tests LED condition Steady green Definition System okay The power source and wire feeder are communicating normally CASE FRONT CONTROL DESCRIPTIONS 1 DUAL DIGITAL DISPLAYS Bright 7 segment dis plays showing welding
45. front panel door This Chart will let the operator provide the proper Electrode Wire size and Weld process for welding POWER FEED 10A CONTROLLER LINCOLN E 6 7 OPERATION B 7 START OPTIONS Pressing the Right Mode Select Panel Pushbutton will illuminate the START OPTIONS LED Repeated pressing of the Right Mode Select Panel Pushbutton will scroll through the parameters Turning the Mode Select Panel Knob while on a parameter will change its value The first settable parameter will be Strike WFS and Volts The Mode Select Panel upper display will be blank and the lower alphanumeric display will read Strike while the Dual Display panel blinks the WFS and Volts LED s prompting the user to enter these parameters Pressing the Right Mode Select Panel pushbutton again will scroll through the Start parameters When the Start Time is set to a value other than OFF the START OPTIONS LED will blink synchronous with the WFS or Amps LED depending on CC or CV Weld Modes and with the Volts LED located on the Dual Display Panel prompting the user to enter these parameters The parameters that can be set by the user in the START OPTIONS will be as follows ARC DELAY TIME MSP4 STRIKE WFS Dual display STRIKE VOLTS Dual Display START WFS AMPS Dual Display START VOLTS Dual Display START TIME MSP4 4 3 Seconds Start Time AC CONTROL Pressing the Left Mode Select Panel Pushbutton while WELD
46. gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo HRUS SIR l RER e HS Sol 2 458 Asis due de Lily Jules c jui Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e 00 548 He ug nisu ALD st yt rap Do nottouch 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 a Aislese del trabajo y de la tierra Ne laissez la peau des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se e terra 9889508388 NARRE FPOHLATMHEVCOE 9 8 7 2 5 ft 4848 ATWSHRIELT FSU E 8 B Oo 6 1610 eai 58 8
47. he POWER FEED 10A CONTROLLER has been shipped standard with all of the wiring and connectivity to connect to the Lincoln K325 TC 3 Travel Carriage 4 pin cable connec tor and the Lincoln K219 Automatic Flux Hopper 3 cable connector The CR2 Relay is wired to the 4 pin travel connector and the CR3 Relay is wired to the 3 pin flux con nector both located on the bottom of the POWER FEED 10A CONTROLLER 115Vac 50 60Hz power is required for the Lincoln auxiliary equipment If either of these is to be used with the POWER FEED 10A CONTROLLER the end user must provide the 115Vac input power to the terminal strip located inside the POWER FEED 10A CONTROLLER Access to the terminal strip may be obtained via the 4 access holes in the bottom of the POWER FEED 10A CONTROLLER These access holes are shipped with plug buttons installed A WARNING Although input power to POWER FEED 10A CON TROLLER is turned off the customer installed auxiliary input may be energized Ensure that all input power to the POWER FEED 10A CONTROLLER is turned off before opening the cover INSTALLATION A 2 SAFETY PRECAUTION A WARNING ELECTRIC SHOCK can kill Only a qualified electrician should connect the POWER FEED 10A CONTROLLER Installation should be made in accordance with the appropriate National Electrical Code the local codes and the infor mation in this manual Turn off the input power to the powe
48. he user in the END OPTIONS will be as follows CRATER WFS AMPS Dual Display CRATER VOLTS Dual Display CRATER TIME MSP4 BURNBACK TIME MSP4 SETUP MODE OPTIONS The Setup Mode can be entered at any time by press ing both Mode Select Panel Pushbuttons simultane ously The SETUP LED will illuminate Pressing both Mode Select Panel Pushbuttons simultaneously while the P number is blinking will exit the Setup Mode The Setup Mode will be exited automatically after 1 minute of inactivity There are two different levels of user preferences in the Setup Mode non secure and secure Accessing secured parameters requires initialization using a Palm or PC utility Welding parameters that will be factory set to default values or adjusted by a relatively small percentage of users will be made available in the SETUP MODE These parameters will include the following STRIKE FAULT TIME MSP4 seconds START ARC FORCE Dual Display Amps DOWNSLOPE TIME MSP4 seconds UPSLOPE TIME MSP4 seconds CRATER ARC FORCE Dual Display Amps WELD ARC FORCE Dual Display Amps POWER FEED 10A CONTROLLER LINCOLN P B 9 OPERATION 8 9 WELD SEQUENCE PARAMETER LIST weld mode dependant Left Dual Display Strike Volts from weld table weld mode dependant Right Dual Display Restrike Time 0 10 0 OF MSP4 SETUP Menu Start WFS Amps weld mode dependant Start Volts weld mode dependant Start Arc Force weld mode dependant WHER
49. he workpiece as close as possible to the area being welded 1 0 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY d ARC RAYS can burn 4 8 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 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 4 FUMES AND GASES can be dangerous 5 8 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep 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 k
50. hen identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page 222 _ Section A Technical Specifi ationiSu A 1 Safely Precaution deceret a etes ai mine A 2 Welding Voltage Mechanical A 2 Locationand MOUFItITIg
51. ines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 b Porter des v tements convenables afin de prot ger la peau
52. ion will not be erased if they are disabled IR PORT SETUP OPERATION B 13 LIMIT SETTING Each user memory can be optionally configured to limit the user s range of control over some user interface set tings By default user limits are not enabled To set lim its for a selected memory first select a weld mode and perform a memory save Next press and hold the mem ory button for five seconds Release the memory button when the memory LED begins to blink rapidly and the Mode Select Panel displays indicate Set Limits If the passcode has been set to a value other than zero the user will be prompted to enter it If the passcode is zero the Mode Select Panel will immediately display the Limit Setup menu and the SETUP LED will illuminate Hl 220 200 LO 180 WELD WFS WELD MODE _ ARC CONTROL SET The above example shows a wire mode constant current weld modes would show Weld Amps rather than Weld WFS IR PORT SETUP START OPTIONS END 5 There are four items displayed on each Limit Setup screen The long alphanumeric display shows the selected attribute e g Weld WFS Volts etc The short alphanumeric displays show the selected attribute s high and low user limits The 7 segment displays show the value that is copied to procedure memory when a memo ry recall is performed High Limit Memory Value y Low Limit 2 HI 220 IR PORT 00 LO 180
53. l warning information throughout this operator s manual and the Engine manual as well POWER FEED 10A CONTROLLER LINCOLN 5 1 TROUBLESHOOTING C 1 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 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 Authorized Field Service Facility This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom
54. limits Machine limits can vary between power sources and are also weld mode dependent The memory value must always be less than or equal to the high limit and greater than or equal to the low limit The high limit must always be greater than or equal to the low limit and the low limit must always be less than or equal to the high limit The rules are enforced automati cally If the low limit is increased above the memory value the memory value will automatically increase To lock an attribute to a specific value set the high and low limits to the desired value The user will not be able to change it After setting limits press the memory button that is flash ing The Mode Select Panel displays will prompt the user to save or discard the limit changes just made By pressing the Mode Select Panel button labeled YES changes to limits are saved and user limits are automati cally enabled By pressing NO any changes made to limits are dicarded and the limit enable disable state is not changed ENABLE LIMITS Yes No WELD MODE 7 START OPTIONS AC CONTROL 7 END options SET To enable or disable limits that have been established for any memory press and hold the respective memory but ton in for more than 10 seconds until the Mode Select Panel displays Enable Limits Pressing Yes will use the established limits while pressing No will ignore the established limits The limits that have been set for any memory locat
55. ll stay illuminated as long as no parameters are changed Once any parameter is changed the corre sponding memory LED will turn off indicating that the stored values are no longer identical to the displayed values However this does not affect the stored val ues in this particular memory location MEMORY SAVING The Memory Panel enables the saving of all weld parameters and all user settable parameters such as timers Start Options End Options AC Controls etc To save a memory press and hold the desired memo ry button for two seconds When the memory button is initially pressed its indicator LED will illuminate POWER FEED 10A CONTROLLER LINCOLN B 13 One of these four items will blink to indicate which item will change when the Mode Select Panel Knob is rotated Initially the selected item will be the attribute To select the high limit press either Mode Select Panel button and the high limit value will begin to blink Pressing either Mode Select Panel button again will cause the memory value to blink pressing a third time will cause the low limit to blink Weld modes cannot be selected from the Limits Setup menu the mode must be selected and saved to memory prior to entering the Limits Setup menu The memory value high and low limit values are bound by the limits of the machine For example weld mode 49 may allow the wire feed speed to be adjusted between 10 and 200 in min These are referred to as machine
56. nderstand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp 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 available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 8 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated ELECTRIC AND MAGNETIC FIELDS 353 may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Wel
57. ntal contact can cause overheating and create a fire hazard 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot
58. p Mode can be used to set more general welding configurations such as travel options or dis play configurations and can be used to access diag nostic tools The POWER FEED 10A CONTROLLER can be configured to display the wire feed speed in inches per minute or meters per minute and or display wire feed speed or Amps in any weld mode To access the wire feed speed units in the Setup Mode enter into the Setup Mode by pressing both Mode Select Panel Pushbuttons simultaneously The SETUP LED will illuminate Turn the Mode Select Panel Knob until WFS UNITS is listed SETUP SETUP WFS Units Travel Ends This item allows the user to reset the consumable weight to the initial weight set in Production Monitoring This option only appears in the list when Production Monitoring is installed in the system Reset Wire P 14 Press the right Mode Select Button to reset left to cancel P 15 Enabled Press the right Mode Select Button Turn the Knob to toggle between Enabled or Disabled This option allows the user to enable or disable touch sense when inching down the wire Disabled Default behavior touch sense is disabled while inching down Enable Touch sensing is enabled while inching down Press the right Mode Select Button Turn the Knob to toggle between English and Metric To set the display to read Wire Feed Speed or Amps turn the Mode Select Knob until ARC DISPLAY MODE is listed SETUP
59. ponsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important w
60. r source at the disconnect switch or fuse box before working on this equipment Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts WELDING VOLTAGE Wire feed parts are electrically live while welding and while inching wire with Touch Sense feature selection The elec trically live parts are listed below Electrode Electrode Reel Wire Drive Motor Drive Rolls Gear Box Cross seam Adjuster Wire Straightener Welding Nozzle Welding Cables Welding Cable Terminal CAUTION e e Do not touch electrically live parts or elec trodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry insulating gloves MECHANICAL HAZARDS e Welding fixture or wire feeder will move during weld ing or inching Keep away from pinch points e Electrode reel and drive rolls turn during welding or inching Keep gloved hands away from areas that may catch the glove LOCATION AND MOUNTING The POWER FEED 10A CONTROLLER will operate in harsh environments Even so it is important that simple pre ventative measures are followed in order to assure long life and reliable operation The POWER FEED 10A CON TROLLER must be located where there is little risk of impacts to the Controller POWER FEED 10A CONTROLLER LINCOLN 8 3 Terminal blocks 48 an
61. ric LED display 2 Thru 5 Allows for machine set up user preferences grouped into secure and non secure categories 6 7 Provides easy access to the multiple weld pro grams inside the Power Wave power sources Pushbutton selection for setting AC parameters 8 Primarily used to change the value of the selected attributes 9 10 Provide complete control of the starting and ending sequence Pushbutton for selecting welding program and parameters WELD PROCESS 4 5 x ci 5 6 7 OPERATION B 6 CHANGING WELD MODES To select a weld mode press the left Mode Select Panel pushbutton 7 until the WELD MODE LED 6 is illuminated it may be illuminated by default at power up Turn the Mode Select Panel Knob 8 until the desired weld mode number 2 is displayed As the Mode Select Panel Knob is rotated only the weld mode number is displayed After 1 second of knob idle time the user interface will change to the selected weld mode and the new mode s welding parameters will be displayed 1 8 IR PORT SETUP CC 60Hz SIN WAVE J WELD MODE START OPTIONS AC CONTROL O END OPTIONS C1 SET MODE SELECT PANEL 4 MSP4 DESCRIPTION IR Infrared Port Weld Mode Number Weld Wire Type Wire Size Weld Mode Description Weld Mode AC Control LED s Selection Pushbutton Weld Mode or AC Control Set Adjustment Dial Knob This table is located on the inside of
62. right Mode Select Panel Pushbutton and see the value set for Start Time If the welder attempts to change its value a message will briefly appear on the Mode Select Panel indicating MSP Option is LOCKED Presently lockout features are only available through a PC application or the IR Port OPERATION 1 21 Shutdown Select Press the right Mode Select Button Turn the Knob to toggle between Standard Shutdown or Output Lockout This option allows the user to use the shutdown 2 input on the control box to lock the welding output in the OFF state but still allow cold feeding of the wire Standard Shutdown Default behavior normal shut down mode prevents cold feed of wire Output Lockout Allows cold feed of wire and pre vents the activation of welding output Pressing the left Mode Select Panel Pushbutton will exit the parameter setting section returning to the previous section Continuing to press the left Mode Select Panel Pushbutton will return to the Setup Mode user preferences and welding parameters list Diagnostic tools SHOW TEST MODES and VIEW DIAGS can be accessed in the Mode Select Panel Setup Mode also but these tools should only be accessed by properly trained personnel INFRARED IR CONTROL The Mode Select Panel interface includes an infrared transceiver This allows wireless machine configura tion using a Palm OS based handheld computer A proprietary Palm OS application ALPalm
63. rors are present in the system Read the error code before the machine is turned off Instructions for reading the error code are detailed in the Service Manual Individual code digits are flashed in red with a long pause between digits If more than one code is present the codes will be separated by a green light To clear the error turn the power source OFF and then back ON to reset See troubleshooting sec tion Non recoverable hardware fault Generally indicates a problem with the cables connecting the wire feeder to the power source Not applicable 4 DUAL ENCODERS Accurately adjust weld parameters as pre set values or on the fly values while welding 5 SWITCH PANEL Heavy duty pushbutton switches that control inching of the wire starting and stopping of weld ing travel and flux control The Switch Panel can be removed and turned into a remote pendant 6 START Activates the weld cycle 7 STOP Deactivates the weld cycle 8 TRAVEL MODE ON Activates travel OFF Disables travel AUTO Activates travel when the START button is pressed Disables travel when the STOP button is pressed 9 FLUX FILL Activates the flux hopper 10 INCH UP Feeds the wire upwards away from the Work POWER FEED 10A CONTROLLER LINCOLN WELD MODE DESCRIPTION 1 Allows wireless machine configuration using a Palm OS based hand held computer 2 Consists of easy to read 36 segment alphanume
64. th a different Weld Mode than the one currently being used will be ignored and an error message will be displayed Up to six different weld procedures can be used while actively welding by using all six memory locations as long as each location utilizes the same Weld Modes This panel performs these functions limit setting and memory saving restoring There are six user memo ries PROCEDURE MEMORY VS USER MEMORY Procedure memory is used while welding Changes to the Power Feed 10A controls immediately change the contents of the selected procedure s memory such as Wire Feed Speed or Volts Procedure memo ry saving is done automatically When the Power Feed 10A is powered up the previous settings at power down will be restored Memory Panel user memories are used as storage and are not directly used while welding When a user memory is recalled the contents of the user memory are copied into the selected procedure where it can be used for welding The user must explicitly save user memories on the Memory Panel MEMORY RECALLING To recall a user memory press and release the desired memory button The memory is recalled when the button is released When recalling a memo ry do not hold the memory button in for more than two seconds A memory cannot be recalled while the out put is enabled The selected memory location 1 6 will illuminate the corresponding LED indicating that this memory location has been recalled The LED wi
65. usty or dirty feeding but drive rolls turning Use only clean electrode Use quality electrode like L 50 or L 56 from Lincoln Electric The contact tip is partially melted If all recommended possible areas of or has spatter Replace the con misadjustment have been checked tact tip and the problem persists Contact your local Lincoln Authorized Improper tip drive rolls and or Field Service Facility inner wire guide Verify the prop er parts are installed Incorrect tension arm pressure on the drive rolls Adjust the tension arm per the Instruction Manual Most electrodes feed well at a tension arm setting of 3 Worn drive roll Replace the drive rolls if worn or filled with dirt CAUTION 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 POWER FEED 10A CONTROLLER LINCOLN 5 E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS Wire feed speed consistently oper 1 The wire feeder gear setting is ates at the wrong value not properly set Verify the soft ware setting matches the gear mounted See the Instruction Manual for setting the gear speed Variable or hunting arc Wrong size worn and or melted contact tip Replace the contact tip Worn work cable or
66. uty cycle is correct Ensure ade quate airflow around power source Long term secondary over 1 The power source has exceeded current the output current limits Adjust the welding procedure to reduce the current draw The welding procedure may exceed the capacity of the power source See the power source Instruction Manual Capacitors are out of bal 1 Verify the power source recon ance nect panel wiring matches the input power 2 See the power source Instruction Manual CAUTION 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 LINCOLN 5 4 TROUBLESHOOTING 4 Observe all Safety Guidelines detailed throughout this manual ARCLINK SYSTEM ERROR CODES Main CPU problem 1 Verify the earth ground connec tion to the power source is wired correctly 2 See the power source Instruction Manual Voltage sense loss 1 Verify correct sense lead connection Short term secondary over current Motor overload long term The wire drive motor has over heated Check that the electrode slides easily through the gun and cable Remove tight bends from the gun and cable Check that the spindle brake is not too tight If all recommended possible areas Verify a high quality electrode 9 misadjustment have be
67. ux Fill Switch Bright high intensity digital read outs Industrial Push Button Switches Switch panel can be removed and remoted into a pendant DEFINITIONS OF WELDING MODES NON SYNERGIC WELDING MODES A Non synergic welding mode requires all welding process variables to be set by the operator SYNERGIC WELDING MODES A Synergic welding mode offers the simplicity of single knob control The machine will select the cor rect voltage and amperage based on the wire feed speed WFS set by the operator COMMON WELDING ABBREVIATIONS SAW e Submerged Arc Welding OPERATION B 1 SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine AA WARNING mu ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground e Always wear dry insulating gloves Do not use AC welder if your cloth ing gloves or work area is damp or if working on under or inside work 9 piece Use the following equipment DC manual stick welder AC welder with reduced voltage control eDo not operate with panels removed Disconnect input power before ser vicing ONLY QUALIFIED PERSONS SHOULD INSTALL USE OR SERVICE THIS EQUIPMENT READ AND FOLLOW THE MANUFACTURER S INSTUCTIONS EMPLOYER S SAFTEY PRACTICES AND MATERI AL SAFTEY DATA SHEETS MSDS FOR CONSUM
68. wire drives Power Feed 10S Wire Drive connects to Lincoln TC 3 Travel Carriage System Interface Phase Generator OPERATION B 2 PRODUCT DESCRIPTION General Physical Description The POWER FEED 10A CONTROLLER is a user interface The control is used to set all welding para meters and control any travel mechanisms High speed digital cables connect the control wire drive and the Power Wave power source together The POWER FEED 10A CONTROLLER is a self contained control box designed to control the entire weld cell at one location The control uses bright digi tal displays encoders and heavy duty pushbuttons designed for every day industrial use The Mode Select Panel utilizes alphanumeric displays for advanced text messaging providing the end user with an intuitive interface allowing for easy set up and real time control of all welding parameters A six button Memory Panel has been included which provides easy storage and recall of stored welding parameters The Switch Panel can be removed from the control box and turned into a Pendant for remote control near the arc General Functional Description POWER FEED 10A CONTROLLER is of the most versatile user interfaces ever created Easy to use features make it a snap to adjust the arc for specific preferences The new Mode Select Panel brightly displays essen tial welding information Use the Mode Select Panel to quickly adjust weld s

Lincoln Electric IM849 User's Manual

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