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Lincoln Electric POWERFEED IM827-D User's Manual

Contents

1. T HOLIMS 30 NOILO3NNOO 900p NMOHS SIHOLIMS 319901 SGI 2134008 40 SN31 40 3903 1 4 ON 722 mes 2 qoo 099 T AAA TANVd 401 9333 la 1 8 0 198 E 3uvds 09 8 0008 4 EN 80 8 3uvds NOLLO3NNOO 3uvds ONISN3S 39V L 10 HOLD AD i 3uvds ld p EET 2 T m m 4 2 m gt g m DIAGRAMS 36 28 gt 212 4 gt 9 53 Od Y31714 1HVHO 138 LS HOLIMS spe 4908324 gt e sar vdSW FE sb 23 _7 WOLS ges ES qe 30b Sid gt V er D i vL sat 2 1 188 310v143934 j d ae kaose gzs 1OHLANY 1004 IVNOLLdO m 926 9890854 gt HAGOON3 e era ee 2 relie AAA i 91 LL Eld 300 SN kd dnm 931504518 94 8
2. BA Bd 0 SEA EYR ea ETSAI BICI x Saal 91 easly ud al gll gail il 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
3. 0 1 Troubleshooting Section E How to Use Troubleshooting Guide 4 E 1 Tr bleshooting G de er tror tet me rl er trt re ee E 2 thru E 13 Wiring Diagram and Dimension eene ennt Section F Parts ASUS c a cisci nias ica Rena BERE RR ERE ERR NER EAR CE ERES ERRARE S idda arinaa aaia P 497 vii INSTALLATION TECHNICAL SPECIFICATIONS Power Feed 10M Single Wire Feeder WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC TYPE LOW SPEED RATIO HIGH SPEED RATIO Wire Size Wire Size Low Speed Solid Cored High Speed Solid 2230 1 50 800 IPM 025 3 32 in 035 120 in 75 1200 IPM 025 1 16 in 035 5 64 in K2314 1 Boom Model 1 27 20 3 m m 0 6 2 4 mm 0 9 3 0 mm 2 0 30 5 m m 0 6 1 6mm 0 9 2 0 mm CONTROL BOX WIRE DRIVE AND COMPLETE UNITS SPEC TYPE INPUT POWER PHYSICAL SIZE TEMPERATURE RATING Dimensions Height Width Depth Weight Operating Storage K2230 1 Wire Drive amp 18 5 13 5 30 5 62 Lbs Bench Reel Stand 470 mm 345 mm 775 28 1 Feeder Dimensions A Height Width Depth Weight K2314 1 Control 40VDC 13 0 8 5 4 0 8 5 Lbs 14 F to 140 F 40 F to 185 F Boom Box only 330 mm 215 mm 105 mm 3 8 Kg 10 C to
4. o O 9 00 229 J 14 20 THREADS MOUNTING Wire Drive Mounting See Figure A 1 The wire drive may be mounted by using the four holes on the bottom Because the feed plate and gearbox are electrically hot when welding make cer tain the parts do not contact the any structure or per son Mount the wire drive with the drive rolls in the vertical plane to prevent dirt from collecting in the wire drive Angle the drive and feed plate to prevent sharp bends in the gun and cable and incoming wire Control Box Mounting See Figure 2 Boom model Power Feed 10M Single Wire Feeder s feature a control box that mounts separately from the wire drive The back of the control box has four keyhole slots for mounting 10 screws are recommended for mount ing FIGURE 2 0 9 POWER FEED 10M SINGLE WIRE FEEDER LINCOLN A 3 SAFETY PRECAUTION ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn off the input power to the power source at the disconnect switch or fuse box before work ing on this equipment Turn off the input power to any other equipment connected to the weld ing system at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts WELD CABLE SIZING Minimum work and electrode cables sizes are as follows
5. SN37 40 3903 LV14 1 LS3HV3N ON 9 933 0334 3uvds 3uvds 3uvds 3uvds 3uvds 3uvds NES e oy oV Sr N ee Ge eS we QN AYVHO ONILLAS LS HOLIMS did 3AIHQ SHIM 4 6111 3009 Y30334 WOOS 3719NIS 2334 HAMOd WVHOVIG SNIHIM Od 431114 385 lt 23 59 lt Sy er 37127193039 9315 1431S c 031 SNLYLS N33H9 034 39und SVD JHONI ON 0 gas 619 6 5 0334 9308 Dd 1 02 POWER FEED 10M SINGLE WIRE FEEDER LINCOLN E WIRE FEEDER BENCH MODEL DIMENSION PRINT DIMENSION PRINT 14 56 j 30 46 Le POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 12 05 DIMENSION PRINT Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel ropa moja da Aislese del trabajo y de la tierra Nelaissez ni la peau ni des v te ments mouill
6. 2 LOCATION euet ein ID 2 2 Safety Pr Ca tiOlis whit d iade tr pe gu dd A 3 Weld Cable SIZING ise mE A 3 Weld Cable Connection sise A 3 lie Ere A 3 iie ER O E A 3 Coaxial Weld EEE a Ieai A A 4 Changing Electrode A 4 Negative Electrode Polarity crise A 4 Control Cable facet intra ati ni nn qe 5 COMO Connection cer p ee n ened 5 Control Cable Specifications ss A 5 Available Control Cable A 5 Wire Drive Systems le es ed A 6 Changing Drive Rolls and Wire Guides rr reenrtrtetrtnnrtintennennennen ne A 6 Drive Roll Pressure Settings A 7 Changing The Gun Receiver Bushing A 7 Welding Gun Torch and Accessories A 8 Wire Feed Shut Down Circuit eene nennen nennen A 9 Changing the Gear Ratio A 9 A 10 Wire Reel Loading ree ecd enne th ene dne ert ere tic dade ert n de Weld Wire Routing Shielding Gas Connection Examples of Connecting an Arclink Power Wave System A 14 eJtupm Section B Sately PIeCautiOns cerea scie
7. 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 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 VE ARC RAYS can burn 4 a 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 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expos
8. The Power Feed 10M Single Wire Feeder Push Pull model comes with a S25398 gun receiver bush ing for use with the push pull gun K2154 1 push pull torch connector kit is optional The bushing must be changed if the Power Feed 10M Single Wire Feeder is going to be switched from the push set up to the push pull set up or vise versa Spool Guns are not recommended with the Power Feed 10M Single Wire Feeder INSTALLATION A 8 MAGNUM GUN AND CABLE ASSEMBLIES The Power Feed 10M Single Wire Feeder model will accept a number of optional gun and cable assemblies An example of installing the Gun and Cable is shown in Figure A 5a with a 15 ft 4 6m long Magnum gun and cable 1 Turn off power at the welding power source 2 Unscrew Thumb screw on Wire Drive Unit until tip of screw no longer protrudes into gun bushing hole as seen from the front of machine 3 Fully insert the gun cable connector end into the gun receiver bushing and gently tighten the thumb screw as show in Figure A 5a below 4 Connect the gun trigger connector to the trigger receptacle Make sure that the key ways are aligned insert and tighten retaining ring FIGURE A 5a GUN AND CABLE TRIGGER RECEPTACLE GUN TRIGGER CONNECTOR GUN RECEIVER BUSHING ai CONNECTOR END K466 10 POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 9 INSTALLATION WIRE FEED SHUT DOWN CIRCUIT The wire feed shut down circuit is use
9. e uil oe us Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas X3TYTTLASU9 UAUNRUS PARKE ETBRAL VY FE e HEMMER AHS Ab alll abil e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes Nao opere com os paineis abertos ou guardas removidas amp TIME Ro ao nelle AREY cus 13 la Jad y e Cut Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR D RMM PBUH A A NHERBEE lt BA LTRHOR MEI TR
10. 1 Make sure the spindle of the wire reel stand is in the upper position 2 With the coil reel assembly mounted to a 2 51mm spindle loosen the spinner nut and remove the cover plate Alternatively lay the coil reel assembly flat on the floor and loosen the spinner nut and remove the cover plate 3 Place the coil of electrode on the reel so it unwinds from the bottom as it rotates PN Tighten the spinner nut as much as possible hand using the cover plate spokes for leverage DO NOT hammer on the spinner nut 5 Cut and remove only the tie wire holding the free end of the coil Hook the free end around the rim of the cover plate and secure it by wrapping it around Cut and remove remaining tie wires CAUTION Always be sure the free end of the is secure ly held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in backlashing of the coil which may tangle the wire A tangled coil will not feed and must either be untangled or discarded 6 Be sure the coil is engaged with the spindle brake pin and the release bar on the retaining collar pops up The retaining collar must fully engage the retaining groove on the spindle POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 12 Loading 30 Ib 13 6 kg Readi Reels See Figure A 11 A K363 P Readi Reel adapter is required for loading these spools on 2 51mm spindles
11. 1 Squeeze the release bar on the retaining collar and remove it from the spindle 2 Place the Readi Reel adapter on the spindle align ing the spindle brake pin with one of the holes in the adapter 3 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle 4 Rotate the spindle and adapter until the retaining spring is at the 12 o clock position 5 Position the Readi Reel so that electrode de reels in the proper direction 6 Set one of the Readi Reel inside cage wires on the slot in the retaining spring 7 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the adapter 8 Slide the cage all way onto the adapter until the retaining spring pops up fully FIGURE 11 ADAPTER RETAINING SPRING INSTALLATION Removing a Readi Reel 1 To remove a Readi Reel from the an adapter depress the retaining spring with a thumb while pulling the Readi Reel cage from the adapter with both hands Do not remove the adapter from the spindle WELD WIRE ROUTING The electrode supply may be either from reels Readi Reels spools or bulk packaged drums or reels Observe the following precautions a The electrode must be routed to the wire drive unit so that the bends in the wire are at a mini mum and also that the force required to pull the wire from the reel into
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13. Avoid sharp corners or bends in the cable The wire is jammed in the gun and cable Remove the gun from the wire feeder and pull the jammed wire out of the gun and cable The gun liner is dirty or worn Blow dirt out of the liner with low pressure 40psi less Replace the liner if worn The electrode is rusty or dirty Use only clean electrode Use quality electrode like L 50 or Super Arc L 56 from Lincoln Electric If all recommended possible areas of misadjustment have been checked The contact tip is partially meltedjand the problem persists Contact or has spatter Replace the con lyour local Lincoln Authorized tact tip Field Service Facility Improper gun liner tip drive rolls and or inner wire guide Verify the proper 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 10M SINGLE WIRE FEEDER LINCOLN 13 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE
14. Postflow Time Adjusts the time that shielding 0 to 25 0 seconds gas flows after the welding out put turns off The burnback time is the amount of time that the weld output continues after the wire stops feeding It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start Crater Procedure controls the Burnback START OPTIONS 0 to 25 Seconds The start Options available in these synergic CV weld modes their adjustment range and function are as follows EFFECT RANGE DESCRIPTION Preflow Time Adjusts the time the gas flows Crater Procedure 0 25 0 seconds Run in WFS Off 30 10150 in min Start Procedure after the trigger is pulled and prior to feeding Run In sets the wire feed speed from the time the trigger is pulled until an arc is estab lished The Start Procedure controls the WFS Trim at a specified time at the beginning of the weld During the start time the machine will ramp up or down from the Start Procedure to the preset Welding Procedure POWER FEED 10M SINGLE WIRE FEEDER Spot Timer 0 to 120 0 Seconds LINCOLN WFS and volts for a specified time at the end of the weld after the trigger is released During the Crater time the machine will ramp up or down from the Weld Procedure to the Crater Procedure Adjusts the time welding will continue even if tigger is still pulled This option has no effect in 4 Step Trigger Mode
15. Power Wave system delivers world class arc performance for a wide variety of processes Using the foundation of Waveform Control Technology each weld mode is precisely tuned to meet exacting standards for low spatter weld bead profile and arc shape OPERATION B 19 Figure B 6 below shows a list of weld modes common on many Power Wave power sources This table is found on the inside front panel door of the Power Feed 10M Single Wire Feeder The specific list of available weld modes depends upon the power source connected to the Power Feed 10M Single Wire Feeder wire feeder CC Stick Mode Customized welding software means even the most CC TIG difficult materials can by welded with the Power CC Gouge Feed Power Wave system Copper Nickel Silicon CV Non Synergic Bronze are just a few of the unusual alloys the Power CV Synergic Feed system welds with ease when special software CV Pulse is loaded CV Pulse on Pulse CV STT FIGURE B 6 GENERAL GMAW STD CV GMAW POWER MODE FCAW STD CV Ar MIX STICK SOFT 7018 Ar MIX STICK CRISP 6010 Ar MIX TOUCH START STT NO TAILOUT GOUGE SIT II ALUMINUM GMAW 4043 PULSE Ar 72 PULSE ON PULSE Ar 0 035 364 1 16 GMAW 74 5356 PULSE Non Synergic Modes CO Ar CO2 CO Ar CO2 STAINLESS 0 030 0 035 0 045 0 052 0 045 GMAW Mix Ar He COz Ar CO2 Ar O2 Ar He CO2 Ar He CO2 Ar He C
16. REEL STAND AND BASE ASSEMBLY BASIC Power Feed 10M Single Wire Feeder WELDING SYSTEM CONFIGURATION CV Welding Pulse Welding or STT Welding Power Source Shielding Gas Hose Work Cable Drive Roll Kit Work Connection POWER FEED 10M SINGLE WIRE FEEDER LINCOLN B 1 OPERATION B 1 SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL Read this entire section of operating instructions before operating the machine WIRE FEEDER Fe POSITIVE OUTPUT ELECTRIC SHOCK can kill Do not touch electrically live parts NEGATIVE OUTPUT or electrodes with your skin or wet clothing Insulate yourself from the work and QD PROTECTIVE ground GROUND Always wear dry insulating gloves E Do not use AC welder if your cloth WARNING OR ing gloves or work area is damp or CAUTION if working on under or inside work piece Use the following equipment DC manual stick welder AC welder with reduced voltage control Do not operate with panels removed Disconnect input power before servicing READ THIS WARNING PROTECT YOURSELF amp OTHERS FUMES AND GASES can be J dangerous Keep your head out of fumes Use ventilation or exhaust at the arc or both to keep fumes and gases from your breathing TL zone and general area WELDING SPARKS can cause fire or explosion Do not weld near flammable material Do not weld on containers which
17. have held flammable material RZ ARC RAYS can burn Wear eye ear and body protection ONLY QUALIFIED PERSONS SHOULD INSTALL USE OR SERVICE THIS EQUIPMENT READ AND FOLLOW THE MANUFACTURER S INSTRUC POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 2 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 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 WFS e Wire Feed Speed cc Constant Current CV e Constant Voltage GMAW MIG Gas Metal Arc Welding GMAW P MIG e Gas Metal Arc Welding Pulse GMAW PP MIG Gas Metal Arc Welding Pulse on Pulse GTAW TIG Gas Tungsten Arc Welding SMAW STICK Shielded Metal Arc Welding FCAW Innershield or Outershield Flux Core Arc Welding HF High Frequency CAG Carbon Arc Gouging OPERATION PRODUCT DESCRIPTION General Physical Description The Power Feed 10M Single Wire Feeder is a mod ular wire feeder consisting of two components a wire drive and a control box are available assem bled as a bench unit or as a boom system High speed highly reliable digital cables connect the com ponents together and to the Power Wave
18. trim value depending upon the welding process mode being used and the status of the wire feeder and power source Below the meter are the words Volts and Trim An LED light illuminates to designate which value is being displayed on the meter The knob below the meter adjusts the value displayed in the meter The following tables describe the function of the Volts Trim display depending upon the status of the wire feeder power source package and the welding process utilized PRIOR TO WELDING Weld Process Volts Trim Display prior to operation Nonsynergic CV Displays the preset Voltage value Displays the preset Voltage value Displays the preset Trim value from 0 50 to 1 50 with 1 00 as the default Trim adjusts the arc length for Pulse programs Lower the trim value to decrease the arc length and raise the trim value to increase the arc length A trim value of 1 00 is optimum for most conditions Synergic CV STT Adjusts the background current of the STT waveform Used to modify the heat input e Linc Net Power Sources Displays the background current as a value from 0 50 to 1 50 with 1 00 as the default Lower the trim value to decrease the heat input and raise the trim value to increase the heat input A trim value of 1 00 is opti mum for most conditions Arc Link Power Sources Displays the background current in amps Lower the background current to decrease the heat input and raise the backgrou
19. 40 C 40 C to 40 C Model Feeder Dimensions A Height Width Depth Weight K2314 1 Wire Drive 7 6 12 9 13 7 30 Lbs Boom Unit only 195 mm 325 mm 345 mm 13 6 Kg Model Feeder WELDING CAPACITY RATING A Dimensions do not include wire reel POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 2 INSTALLATION A 2 SAFETY PRECAUTION ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn off the input power to the power 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 LOCATION The Power Feed 10M Single Wire Feeder has 1 21 rating suitable for indoor use The Power Feed 10M Single Wire Feeder should be operated in a substantially upright position Do not submerge the Power Feed 10M Single Wire Feeder The Power Feed 10M Single Wire Feeder is not suitable for stacking Locate the Power Feed 10M Single Wire Feeder away from radio controlled machinery The normal operation of the Power Feed 10M Single Wire Feeder may adversely affect the operation of RF con trolled equipment which may result in bodily injury or damage to the equipment FIGURE A 1 4 75 121 mm
20. Amperage 120 OFF VOLTS TRIM Q The system supports both TIG torches with or without gas control valves TIG torches with gas control valves connect directly to the gas flow regulator For TIG torches without gas control valves connect the output gas hose on the Power Feed 10M Single Wire Feeder While TIG welding the right encoder can only turn output on and off in 2 step only Turning the right encoder while 4 step TIG is selected will cause a message to be dis played indicating that on off output control is only available in 2 step TIG Touch Start TIG Weld Sequence No Foot Hand Amptrol With Foot Hand Amptrol Adjust the arc amperage with the left knob 1 on the display panel Turn the right knob on the display panelj2 TIG torches without 3 until the Output Control is ON Gas will 3 start to flow Touch the tungsten to the work piece Lift the tungsten to create an arc and 5 Stop welding by turning the Output Control to OFF or by pulling away the tungsten 6 from the work Gas flow will continue for a short time and then shut off Adjust the arc amperage with the left knob 1 on the display panel Turn the right knob on the display panelj2 until the Output Control is ON Open the gas valve on the TIG torch TIG torches with built in Gas Valves Touch the tungsten to the work piece Lift the tungsten to create an arc an
21. COURSE OF ACTION Wire feed speed consistently 1 The wire feeder gear setting is ates at the wrong value not properly set Verify the Power Feed 10M Single Wire Feeder software setting matches the gear mounted See the Instruction Manual for setting the gear speed Variable or hunting arc 1 Wrong size worn and or melted contact tip Replace the contact tip 2 Worn work cable or poor work connection Verify all work and electrode connections are tight and that the cables are in good condition Clean replace as nec essary 3 Wrong polarity Adjust polarity to the recommended procedure Verify DIP switch 7 setting matches the electrode polarity 4 The gas nozzle is extended If all recommended possible areas of misadjustment have been checked and the problem persists Contact beyond the contact tip or the wire your local Lincoln Authorized stickout is too long Adjust the gas nozzle and shorten the con tact tip to work distance 1 2 to 3 8 inches 5 Poor gas shielding on processes requiring gas Check gas flow and mixture Remove or block sources of drafts Poor arc starts with sticking or 1 Improper procedures or tech blast offs weld porosity narrow niques See Gas Metal Arc and ropy looking bead Welding Guide GS 100 Field Service Facility CAUTION If any reason you understand the test procedures or are unable to perform the tests repairs safely
22. FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 749 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 ne 1 h To avoid scalding do not remove the Ol opis radiator pressure cap when the engine is powered equipment ANN V OE ip 9 1 a Turn the engine off before troubleshooting and maintenance lt work unless the maintenance work requires to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes ay outdoors AR ELECTRIC AND SR MAGNETIC FIELDS 1 c Do not add the fuel near an open flame S may be dangerous welding arc or when the engine is running Stop the engine and allow it to cool before 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz localized Electric and Magnetic Fields EMF Weldin
23. FUNCTION 200 WES AMPS 0 25 0 seconds Adjusts the time the gas flows after the trigger is pulled and prior to feeding wire LESS MORE Off 30 10150 in min i i DEPOSITION DEPOSITION Run in sets the wire feed speed from the time the trigger is pulled until an arc is estab lished EFFECT RANGE DESCRIPTION PEAK CURRENT Peak Current acts similar to an Ba e arc pinch control Peak Current the weld During the start time the p machine will ramp up or down currani levers MINEURS from the Start a to the the arc to broaden momentarily t Welding P d while increasing arc length If set too high globular transfer END OPTIONS May occur Setting I too To ARAMETER RANGE FUNCTION may cause instability and wire Postflow Time i ae 0 to 10 seconds Adjusts the time that shielding gas P flows after the welding output puddle agitation e df BACKGROUND Background Current controls Crater Procedure Crater Procedure controls the WFS and volts for a specified time at the end of the weld after the trigger is released During the Crater time the machine will ramp up or down from the Weld Procedure to Crater Procedure Burnback The burnback time is the amount 0 to 25 Seconds of time that the weld output contin ues after the wire stops feeding It prevents the wire from sticking in the puddle and prepares the end of
24. Spot Timer 0 to 120 0 Seconds POWER FEED 10M SINGLE WIRE FEEDER LINCOLN gas flows after the welding out put turns off Crater Procedure controls the WFS and Volts for a specified time at the end of the weld after the trigger is released During the Crater time the machine will ramp up or down from the Weld Procedure to the Crater Procedure The burnback time is the amount of time that the weld output continues after the wire stops feeding It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start Adjusts the time welding will continue even if tigger is still pulled This option has no effect in 4 Step Trigger Mode 24 OPERATION B 24 MACHINE FUNCTIONALITY BY WELD PROCESS GMAW SYNERGIC Use the following tables to review how the machine functions output controls arc control Start options and weld options for the weld modes listed in the top table SYNERGIC CV MODES MATERIAL PROCESS WIRE SIZE 0 030 0 035 0 ms 0 552 GMAW a Aluminum 4043 1 Aluminum 5356 Ar 151 75 amaw m m OUTPUT CONTROL KNOBS 200 _ 26 3 Oof WFS AMPS VOLTS TRIM RD CRD LESS MORE LESS MORE WFS WFS VOLTS VOLTS ARC CONTROL PINCH EFFECT Adjust the short circuit current 10 0 to 10 0 to create a soft arc or a force ful digging arc END OPTIONS EFFECT RANGE DESCRIPTION
25. alphanumeric LED dis play The information shown on the various displays depends on the state of the user interface as described below When the MSP4 is being used to select a weld mode the 4 digit display Item 2 indicates the selected weld mode number The upper 8 character alphanumeric display Item 3 indicates the electrode type steel aluminum etc The lower 8 character alphanumeric display Item 4 indicates the electrode size 035 1 16 etc POWER FEED 10M SINGLE WIRE FEEDER LINCOLN B 8 OPERATION B 8 The 16 character alphanumeric display Item 5 indi cates the process type and other information the exact content of which depends on the selected weld mode This additional information may include specific electrode type e g 4043 and or a description of the recommended gas e g HeArCO2 When the MSP4 is being used to change the value of an attribute the 7 segment displays show the select ed attribute s value The upper 8 character alphanu meric display is typically not used while changing an attribute s value The lower 8 character alphanumeric display is used to indicate the units of the selected attribute e g seconds in min etc The 16 character alphanumeric display is used to display the name of the selected attribute The content of the displays while the user interface is being used for advance machine configuration e g limit setting pass code entering machine setup etc is de
26. and the status of the wire feeder and power source Written below the display is WFS and Amps An LED light illuminates which value is being displayed on the meter The knob below the meter adjusts the value displayed on the meters CC Welding Processes Meter displays the preset Amps During Welding An Weld Processes Meter displays displays the actual average welding Amps After Welding An Weld Processes The meter holds the actual current value for 5 sec onds The display blinks to indicate the Power Feed 10M Single Wire Feeder is in the Hold period If the output is adjusted while in the Hold period the Power Feed 10M Single Wire Feeder will revert to the Prior to welding dis play described above Note If the output knob for the WFS AMPS is adjust ed while the Power Feed 10M Single Wire Feeder is in the Hold period the Power Feed 10M Single Wire Feeder will immediately revert to the Prior to Welding display The default wire feed speed units are inches minute and can be changed to meters minute by entering the Set up Menu in this Operation Section The wire feed speed is calibrated to within 2 Refer to the power source man ual for calibration specifications of the ammeter POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 6 OPERATION B 6 B VOLTS TRIM DISPLAY AND OUTPUT KNOB The voltage trim meter displays either the voltage or
27. at 75 1200 ipm 025 1 16 in 035 564 X Washers holding the gear to the shaft high wire feed 2 03 30 5 0 6 1 6 mm 0 9 2 0 mm 5 Remove the gear speeds Feeding force is less High Speed 6 Lightly cover the shaft with engine oil or equivalent Install the desired gear onto the shaft 7 Reassemble the screw and washers securing the gear to the shaft 8 Reassemble the screws in the appropriate position for holding the feed plate to the wire feeder POWER FEED 10M SINGLE WIRE FEEDER LINCOLN CLAMPING COLLAR SCREWS LOW SPEED SCREW SETTING HIGH SPEED SCREW SETTING SCREW FOR ROTATING FEED PLATE 9 Loosen the two screws on the bottom of the feed plate clamping collar 10 Rotate the feed plate to the desired position 11 Tighten the two screws on the bottom of the feed plate clamping collar FIGURE 7 High speed Low speed default 12 Remove the rear access panel on the wire drive 13 Locate DIP switches on the Wire Drive Board 14 Set DIP switch 8 to the desired polarity 15 Reinstall the rear access panel to the wire drive 16 Restore power INSTALLATION WIRE REEL LOADING Spindle Placement The wire reel stand provides two mounting locations for the spindle Each mounting location consists of a tube in the center of the mast and locating slots Loading 16 to 44 Ib 7 3 20kg Spools 1 Squeeze the release bar on the retaining
28. contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10M SINGLE WIRE FEEDER LINCOLN Jequinu epoo jueuudinbe 9 e 10 BdIAIBS 2 eui sjaued einsoj oue y euo uo 1 E y paysed si epoo e 40 y enueui siy 20 2 eq jou AJUO 10 S SIUL 3 LON 657 TeNOUIdO 3129143238 H 3oqdiug LAN ONIT 1Nd1NO nca MNITOHV Old 2 seran ir ter Herr auvos 9 4 JO 318 LN3NOdWOO G3M3IA SONSNOAS SNIH3SARDN ALIAVO 9333 2d TOHINOD DEP N gt oors 9008 Lo gt oNS SLIHM M 3n18 n Movi8 8 SNIGOO Qv31 16913 SIOSWAS 1V91H19373 NOILVWHOSNI TVH3N39 LE o XS 3SN3S SOVLIOA 900 0 007 7 O d 109135 JH XO8 TOHLNOD XO8OHLNOD 59 259 300 i 4 b gt J Ke 01108
29. exit the set up menu FIGURE B 3a SETUP MENU Mode Select Panel MSP4 LED Indicator buttom button SET Knob POWER FEED 10M SINGLE WIRE FEEDER LINCOLN B 11 USER DEFINED PARAMETERS Exit Setup Menu This setup menu parameter can be used to exit the setup menu When 0 is displayed press the left Mode Select button to exit the setup menu Wire Feed Speed Units P 1 selects which units wire feed speed will be displayed in English in minute wire feed speed units default Metric m minute wire feed speed units Arc Display Mode P 2 selects what value will be shown on the upper left display while welding Amps The left display shows Amperage while welding default WFS The left display shows Wire Feed Speed while welding Display Energy P 3 selects whether or not energy is displayed on the MSP4 while welding The total energy from the previous weld will persist on the MSP4 display until another weld is started or a user interface control is changed P 3 will only show up in the list if the power source is capable of calculating energy a power source software update may be necessary When P 3 No ener gy will not be displayed default When P 3 Yes energy is displayed Recall Memory with Trigger Allows the operator to recall a memory by quickly pulling and releasing the gun trigger To recall a memory quickly pull and release the trigger the number of times that correspond to the m
30. most GTAW welding procedures and some Innershield procedures 67 amp 21 An electrode sense lead and work sense lead are connected Hardware Config The hardware determines the best remote sensing configuration This is applicable to MIG welding procedures only Voltage Sense Display Allows viewing of Voltage Sense Lead Selection to aid in troubleshooting The configuration is displayed as a text string on the MSP display whenever the output is enabled This parameter is not saved on a power cycle but will be reset to False POWER FEED 10M SINGLE WIRE FEEDER LINCOLN Bd OPERATION 15 USER DEFINED PARAMETERS Show Test Modes Most power sources contain weld modes used for calibration and test purposes By default the machine does not include test weld modes in the list of weld modes that are available to the operator To manually select a test weld mode set this option to Yes When the power source is turned off and back on again the test modes will no longer appear in the mode list Test weld modes typically require the machine out put to be connected to a grid load and cannot be used for welding View Diagnostics Diagnostics are only used for servicing or troubleshooting the Power Wave system Select Yes to access the diagnostic options in the menu Additional parameters will now appear in the setup menu P 101 P 102 etc View Event Logs Used for viewing all the system event logs Press the right M
31. of length xx K1500 1 Gun Receiver Bushing for guns Includes Gun receiver bush with K466 1 Lincoln gun connec ing set screw and hex key tors Innershield and Subarc guns wrench K1500 2 Gun Receiver Bushing for guns Includes Gun receiver bush with K466 2 K466 10 Lincoln gun ing with hose nipple set screw connectors Magnum 200 300 400 and hex key wrench guns and compatible with Tweco 4 Gun Receiver Bushing for guns with K1637 7 Lincoln gun connec Includes Gun receiver bush K1500 3 tors Magnum 550 guns and com ing with hose nipple set screw patible with Tweco 5 and hex key wrench POWER FEED 10M SINGLE WIRE FEEDER LINCOLN C 2 ACCESSORIES 2 1500 4 Gun Receiver Bushing for gun Includes Gun receiver bush with K466 3 Lincoln gun connec ing with hose nipple set screw tors compatible with Miller amp guns and hex key wrench Includes Gun receiver bush Gun Receiver Bushing compatible ing with hose nipple 4 guide with Oxo guns tubes set screw and hex key wrench Gun Receiver Bushing for Lincoln Includes Gun receiver bush Fast Mate guns ing with trigger connector Magnum 200 300 400 to K1500 2 Includes Gun adapter cotter Adapter pin hex key wrench wrench Magnum 550 to K1500 3 Adapter Includes Trigger adapter gun adapter and hex key wrench K1546 1 Incoming Bushing Lincoln Conduit Includes Incoming bushing 025 1 16 and hex key wr
32. 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 Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding
33. output and the wire feed speed continue at the Weld settings 6 DOWNSLOPE Then as soon as the trigger is pulled the wire feed speed and power source out put ramp to the crater settings during the crater time The time period of ramping from the weld set tings to the crater settings is called DOWNSLOPE 7 CRATER Alter the Downslope time expires the machine welds at the Crater WFS and voltage set tings until ether the trigger is released or the Crater time expires 8 BURNBACK After the crater time expires the wire feed speed is turned OFF and the machine output continues for the burnback time 9 POSTFLOW Next the machine output is turned OFF and shielding gas continues to flow until the post flow timer expires D 3 3 E E 8 5 5 o 5 a E 7 2 8 8 E lt E Ide Preflow Strike Upslope Weld Downslope Crater Burnback Postflow A Onn i Shielding fon Gas ee Weld acne 1 Burnback i j 1 L1 J4 L 1 7 comm rc om mm Source Start mE a Output crater ence eee Off Weld Start L 4 Hes WFS Crater Lam m m IQQ Strike ommo o POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 19 PROCESS SETUP AND OPERATION The Power Feed
34. power source for pipe thawing LINCOLN 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 CGA publication P l 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 equipm
35. s entrer en contact avec des pi ces sous tension solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e solieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e electro dos com a pele ou roupa molhada sole se da pe a e terra e EPOT S NAHE Z7 bnf dcolnituect ATUSHRELTFEL CRA CRM ML ATAH SASS Je Jy yra uu 9 AAS ASA OAR Mi gay Quali Y ead alga ji ril ee aul DE Y Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e Hav v6008 CO8I TEX CEU EA e 18 9 Z VAM T SRE LFB AT ects 248 YZ AIX nig ALI al gll a e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo e ARR HRAEBSHRRAR ez 119 0 dil die Lily jules e T 3 READ AND UNDERSTAND THE MANUFACTUR
36. the wire for the next arc start Spot Timer Adjusts the time welding will con to 120 0 Seconds tinue even if tigger is still pulled This option has no effect in 4 Step Trigger Mode CURRENT the overall heat input in the weld High background cur rents flatten the weld bead and low background currents create a taller rounded con tour TAIL OUT Tail out provides additional STT Il MODES power without the molten ONLY droplet becoming too large Increase as necessary to add heat input without increasing arc length Often this results in faster travel speeds Note that as tail out increases the peak current and or background cur rent may need to be reduced POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 27 OPERATION B 27 MACHINE FUNCTIONALITY BY WELD PROCESS GTAW Touch Start TIG Welding Use the following tables to review how the machine functions output controls arc control Start options and weld options for the weld modes listed in the top table TOUCH START TIG PROCESS MODE Touch Start TIG OUTPUT CONTROL KNOBS Output Control Material All Metals ARC CONTROL No Arc Controls are active for Touch Start TIG START OPTIONS START PROCEDURE The Start Procedure controls the Amperage at a fixed level for the set amount of time END OPTIONS Ool WFS AMPS n GTAW TIG WELDING The Power Feed Power Wave system is excellent for Touch Start TIG welding Maximum
37. to EMF fields from the welding circuit 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 body 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 the workpiece as close as possible to the area being welded Do not work next to welding power source ELECTRIC SHOCK can kill 3 a 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 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
38. trigger If desired memories 2 through 6 can be recalled with the gun trigger For example to recall memory 3 quickly pull and release the gun trigger 3 times without welding Note the Power Feed 10M Single Wire Feeder is factory set with this feature disabled Use the SETUP menu and change P 4 to enable memory recall with the gun trigger Save a memory with memory buttons To save a memory press and hold the desired memo ry button for two seconds When the button is initially pressed the corresponding LED will illuminate After two seconds the LED will turn off Do not hold the button for more than 5 seconds when saving a user memory Note that memories may be locked in the Setup menu to prevent accidental overwrite of the memories If an attempt is made to save a memory when memory sav ing is locked the message Memory save is Disabled will appear briefly in the MSP4 display RECALL PRESS 1 SECOND SAVE PRESS 2 SECONDS MEMORY de HOLD 2 SECONDS TO SAVE OPERATION B 28 6 OPTIONAL DUAL PROCEDURE MEMORY PANEL OPERATION The Dual Procedure Memory Panel performs three functions Weld procedure selection Memory save and recall Limits setting There are two procedure memories A and B and six user memories 1 6 Procedure Memory vs User Memory Procedure memory is used while welding Changes to the weld procedure
39. using the WFS knob Hold with toggle switch in the DOWN position to activate Gas Purge and let the shielding gas flow The gas sole noid valve will energize but neither the power source out put nor the drive motor will be turned on The Gas Purge switch is useful for setting the proper flow rate of shield ing gas Flow meters should always be adjusted while the shielding gas is flowing OPERATION 5 2 STEP 4 STEP TRIGGER SWITCH The 2 Step 4 Step switch has two set positions Place the switch in the UP posi tion for 2 step Trigger Operation and in the down position for 4 step Trigger Operation 2 Step Trigger 2 Step trigger operation is the most com mon When the gun trigger is pulled the welding system power source and wire feeder cycles through the arc starting sequence and into the main welding para meters The welding system will continue to weld as long as the gun trigger is activated Once the trigger is released the welding system cycles through the arc ending steps 4 STEP 4 Step Trigger Operation When the switch is in the 4 Step position the Power Feed 10M Single Wire Feeder provides trigger inter lock capability the operator can release the trigger and the system will continue to weld and it also allows the operator to control the amount of time spent in the start and crater weld modes See Sequence of Operation for more information on the overall interaction trigger switch with the weld seq
40. 25 OPERATION B 25 MACHINE FUNCTIONALITY BY WELD PROCESS PULSE AND PULSE ON PULSE SYNERGIC Use the following tables to review how the machine functions output controls arc control Start options and weld options for the weld modes listed in the top table MATERIAL PROCESS ALUMINUM 404 ALUMINUM 404 ALUMINUM 535 ALUMINUM 535 Pulse Pulse on Pulse PULSE AND PULSE 0N PULSE MODES Pulse on Pulse 98 99 100 WIRE SIZE 0 035 3 64 1 16 149 72 74 152 76 78 101 102 103 OUTPUT CONTROL KNOBS WFS AMPS LESS MORE WFS WFS ARC CONTROL PULSE DESCRIPTION FREQUENCY Low 10 0 to For Pulse modes Arc Control High 10 0 changes the pulsing frequency When the frequency changes the Power Wave system auto matically adjusts the back ground current to maintain a similar heat input into the weld Low frequencies give more con trol over the puddle and high frequencies minimize spatter START OPTIONS PREFLOW TIME DESCRIPTION 0 25 0 seconds Adjusts the time the gas flows after the trigger is pulled and prior to feeding wire RUN IN WES Off 30 to150 in min Run in sets the wire feed speed from the time the trigger is pulled until an arc is estab lished The Start Procedure controls the WFS Trim at a specified time at the beginning of the weld During the start time the machine will ramp up or down from
41. ER 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 ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaustao para remover fumo da zona respirat ria RACE TIBELTTFEL OR ames 1c OF OR OX HEEL SR ER TR S SWA s amp xiossH HHSHP HS THARA dE faa duly e bia gs 4 92
42. ERS Push Pull Gun Knob Behavior Determines how the potentiometer on the Push Pull torch will behave Gun Pot Enabled The welding wire feed speed is always controlled by the potentiometer on the push pull gun default The left front panel knob is only used to adjust Start and Crater wire feed speed Gun Pot Disabled The wire feed speed is always controlled by the left front panel knob This setting is useful when the operator wishes to have wire feed speed settings recalled from memories and not have the potentiometer overwrite the setting Gun Pot Procedure When in procedure A the welding wire feed speed is controlled by the poten tiometer on the push pull gun When in procedure B the welding wire feed speed is controlled by the left front panel knob This setting allows a fixed wire feed speed to be selected in procedure B and not have the potentiometer overwrite the setting when procedure changes Display Trim as Volts Option Determines how trim is displayed False The trim is displayed in the format defined in the weld set default True All trim values are displayed as a voltage Arc Start Loss Error Time Can be used to optionally shut off output if an arc is not established or is lost for a specified amount of time Error 269 will be displayed if the machine times out If the value is set to OFF machine output will not be turned off if an arc is not established nor will output be turned off if an arc is
43. ES 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 WAVEFORM CONTROL TECHNOLOGY Enable Limits No WELD MODE START OPTIONS ARC CONTROL END oPrioNS 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 location will not be erased if they are disabled IR PORT SETUP y Yes POWER FEED 10M SINGLE WIRE FEEDER LINCOLN ACCESSORIES C1 OPTIONAL Includes Push Pull Gun Receiver Bushing Fittings K2339 1 Push Pull Connection Kit Modified Gas Bypass Valve Valve Removal Tool and Control Cable Extension Assembly Includes 1 connector for connecting K2429 1 ArcLink T Cable Connector 2 Wire Feeders to 1 Power Source K2360 1 Dual Procedure Memory Panel Includes 1 memory panel K1543 xx ArcLink Cables Includes 1 ArcLink cable of length xx K1796 xx Co Axial Power Cable Includes 1 Coaxial weld cable of length xx Ends of the weld cable have lug connections K1842 xx Weld Power Cable Includes Lug to Lug 3 0 Cable
44. GMAW CV GMAW POWER MODE OUTPUT CONTROL KNOBS WELD MODE 5 amp 6 300 of WFS 25 3 O VOLTS CD LESS MORE LESS MORE WES WFS VOLTS VOLTS AMPS TRIM ARC CONTROL EFFECT RANGE Soft 10 0 to Crisp 10 0 DESCRIPTION Arc Force adjusts the short cir cuit current for a soft arc or for a forceful digging arc START OPTIONS The start Options available in these Non Synergic CV weld modes their adjustment range and function are as follows EFFECT RANGE DESCRIPTION Preflow Time Adjusts the time the gas flows 0 25 0 seconds after the trigger is pulled and prior to feeding WFS Run In sets the wire feed Off 30 to150 in min speed from the time the trigger is pulled until an arc is estab lished The Start Procedure controls the WFS and Volts for a speci fied time at the beginning of the weld During the start time the machine will ramp up or down from the Start Procedure to preset Welding Procedure Start Procedure 0 10 seconds FCAW CV 5 40 WELD MODE OUTPUT CONTROL KNOBS WELD MODE 40 200 2 0 WFS AMPS LESS MORE WFS VOLTS TRIM LONGER ARC SHORTER ARC END OPTIONS EFFECT RANGE DESCRIPTION Adjusts the time that shielding Postflow Time 0 to 25 0 seconds Crater Procedure 0 TO 10 0 SECONDS Burnback 0 to 25 Seconds
45. M Single Wire Feeder To verify the wire feed speed Assemble a 045 1 2mm drive roll kit into the Power Feed 10M Single Wire Feeder Load a spool of 045 1 2mm electrode and thread the electrode through the wire drive e Adjust the wire feed speed to 300 in min 7 62m min e Press the COLD FEED switch and measure the actual wire feed speed with a calibrated wire feed Speed tachometer The measured wire feed speed should be within 2 of the set value POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 1 TROUBLESHOOTING E 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below 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 Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that
46. Microprocessor RAM error in Turn Power off at power source Control Box Wait 5 seconds Turn power back on If Err 211 is displayed again then replace CB mother PC board Microproceeor RAM Error in object Cycle power as in Err 211 If Err board other than Control Box Such 212 is still displayed then replace as feed head PC board in the object with fault The object with the fault should be solid red on its status LED THREE DASHES Appears on right display of CB mod Dashes indicate that the encoder ule that contains the status Led does not control anything including on off output control 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 10M SINGLE WIRE FEEDER LINCOLN 8 TROUBLESHOOTING E 8 Observe all Safety Guidelines detailed throughout this manual LINC NET SYSTEM ERROR CODES The wire feeder has not received a recognition command from the Check to see if the STATUS LED on power source Verify the power Power Wave 455 is not steady source is operating properly green If it is not steady green refer Status light steady green to the Power Wave 455 Status LED Chart and Code Table Check the Check control cable for loose or Control cables for loose or faulty con broken leads nections Als
47. NCOLN DIP Switch 7 Position negative pola postive FIGURE A 3 CONTROL CABLE CONTROL CABLE CONNECTIONS All system control cables are the same All control cables can be connected end to end to extend their length All system equipment must be connected to con trol cable Typical Bench Feeder Connection Control cable is connected from the Power Wave Source output Amphenol receptacle to the input Amphenol receptacle on the back of the Wire Drive Digital Control Cable K1543 xx Power Source Wire Feeder Amphenol Plug Amphenol Plug Digital 1 0 IB Digital VO 67 voltage sense 40 VDC 40 VDC Use a maximum of 250 feet 76 2m of control cable between components INSTALLATION A 5 Welding Gun Wire Feeder Trigger Connector Wire Feeder Amphenol Welding Gun Wire Feeder E _ D Dual Procedure CONTROL CABLE SPECIFICATIONS It is recommended that only genuine Lincoln control cables be used at all times Lincoln cables are specifi cally designed for the communication and power needs of the Power Wave Source Power Feed sys tem The use of non standard cables especially in lengths greater than 25ft 7 6m can lead to communi cation problems system shutdowns poor motor acceleration poor arc starting and low wire driving force wire feeding problems Lincoln control cables are copper 5 conductor cable in a SO type rubber jacket Ther
48. No shielding gas Replace the power switch The gas supply is OFF or empty Verify the gas supply is ON and flowing The gas hose is cut or crushed Route the gas hose so it avoids sharp corners and make sure nothing is on top of it Repair or replace damaged hoses Dirt or debris is in the solenoid Apply filtered shop at 80psi to the solenoid to remove dirt There is a loose solenoid connec tion Remove the cover and check that all connections are in good condition The solenoid has failed Check for 40VDC at J81 leads 540 and 500 If voltage is pre sent replace P C BD If voltage not present check leads from J81 on BD to Input 5 pin connector Refer to machine schematic Check for 6 5VDC with trigger pulled at J83 leads 553 and 554 If voltage is present replace solenoid If voltage is not present replace P C BD Refer to machine schematic 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 10M SINGLE WIRE FEEDER LINCOLN 12 TROUBLESHOOTING E 12 Observe all Safety Guidelines detailed throughout this manual Inconsistent wire feeding or wire not 1 The gun cable is kinked and or feeding but drive rolls turning twisted Keep the gun cable as straight as possible
49. O2 0 035 3 64 1 0 048 0 052 1 16 GMAW 81 PULSE Ar CO 82 Synergic Modes POWER FEED 10M SINGLE WIRE FEEDER LINCOLN B 20 OPERATION B 20 STEEL AND STAINLESS SYNERGIC GMAW P PULSED MIG WELDING Synergic GMAW P Pulsed MIG welding is ideal for low spatter out of position and reduced heat input applica tions During pulse welding the welding current continuously switches from a low level to a high level and then back again Each pulse sends a small droplet of molten metal from the wire to the weld puddle Pulse welding controls the arc length with Trim instead of voltage When trim arc length is adjusted the Power Wave automatically recalculates the voltage current and time of each part of the pulse waveform for the best result Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 for a 3 4 19mm electrode stick out Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length FIGURE B 7a Trim 50 Trim 1 00 Trim 1 50 Arc Length Short Arc Length Medium Arc Length Long ARC CONTROL For steel and stainless pulse modes Arc Control regulates the focus or shape of the arc Arc Control values greater than 0 0 increase the pulse frequency while decreasing the background current resulting in a tight stiff arc best for high speed sheet metal welding Arc Control values less than 0 0 decrease the pulse frequency while increasing th
50. POWER FEED 10M WIRE FEEDER n For use with machines having Code Numbers 11086 11193 11216 11439 11771 11772 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 thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL ee a 150 9001 mm H Inc d Manufactured Under a ogra d by Copyright O Lincoln Global Inc LINCOLN amp World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 1 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com WARNING A CALIFORNIA PROPOSITION 65 WARNINGS 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
51. ROL LED is illuminated The value name and units if applicable of the available wave con trols will appear Note that the name of the control is derived from the weld table and may not necessarily appear as Wave Control Repeated pressing of the left MSP4 pushbutton will cycle through all active wave con trols and then the weld mode Turning the MSP4 encoder will change the value of the displayed wave control CHANGING WELD SEQUENCE BEHAVIOR Weld sequencing attributes are grouped into two cate gories START OPTIONS and END OPTIONS START OPTIONS may include Preflow Time Run in Wire Feed Speed and Start Time END OPTIONS may include Spot Timer Crater Time Burnback Time and Postflow Time The attributes that appear in the START and END OPTIONS are weld mode dependent For example if a TIG weld mode is selected Run in WFS will not appear since it is not relevant to the selected process Repeated pressing of the right MSP4 pushbutton will cycle through all relevant START and END OPTIONS Turning the MSP4 encoder will change the value of the selected option When the Start Time attribute is set to a value other than OFF the START OPTIONS LED will blink synchronous with the WFS and VOLTS TRIM LED s on the dual dis play panel This blinking is used to indicate that start wire feed speed and voltage trim can now be set to values dif ferent from those used while welding Similarly if the Crater Time attribute is set to a value othe
52. S CASE FRONT CONTROLS FIGURE B 1 Un iL c 9e j BO ITEM DESCRIPTION Status LED indicates system status Digital Meter Display is a bright LED display of key welding information Adjusting Parameter Knobs MSP4 Panel is used to set the weld mode adjust the arc change arc start end parameters and for set up information 4 Cold Feed Gas Purge Switch press the switch up to feed wire with weld output off Press the switch down for gas flow with weld output off 2 step 4 step Switch is used to choose between a 2 step trigger or a 4 step trigger operation Memory Panel Operating Instructions are located in this Operation Section if your machine is equipped with this unit If not equipped you may order K2360 1 Field Installed option See Accessories Section Memory Panel are for Codes 11771 11772 and above Cover for Optional Water Cooling Kit remove when the water cooling kit is installed See instructions with water cooling Kit 8 Trigger Connector 5 pin amphenol for connecting the MIG gun trigger See Installation Section for detail POWER FEED 10M SINGLE WIRE FEEDER LINCOLN B 5 OPERATION B 5 1 STATUS LED The status LED indicates system status operation is a steady green light Normal Note During normal power up the LED may flash red and or green as the equipment performs self tests wire feeder are communicating nor mally Bli
53. SP Button to enter the option Rotate Set knob to select the desired system log to read Press the right button again to enter the selected log Rotating the Set knob will scroll through the event log displaying the log index number event code and some other data Press the left button to back out to select another log Press the left button again to exit this option View Fatal Logs Used for viewing all the system fatal logs Press the right MSP Button to enter the option Rotate Set knob to select the desired log to read Press the right button again to enter that log Rotating the Set knob will scroll through the log displaying the log index number and fatal code Press the left button to back out to select another log Press the left button again to exit this option View Software Version Information Used for viewing the firmware versions for each board in the system Press the right MSP Button to enter the option Rotate Set knob to select the desired board to read Press the right button again to read the firmware version Press the left button to back out to select another board Rotate the SET knob to select another board or press the left button to exit this option View Hardware Version Information Used for viewing the hardware version for each board in the system Press the right MSP Button to enter the option Rotate Set knob to select the desired board to read Press the right button again to read the hardware version Press the lef
54. TABLE A 1 Current 60 Duty Cycle MINIMUM COPPER WORK CABLE SIZE AWG Up To 100 Ft Length 30 m 400 Amps 500 Amps 600 Amps 2 0 67 mm2 3 0 85 mm2 3 0 85 mm2 NOTE K1796 coaxial welding cable is recommended to reduce the cable inductance in long distance Pulse or STT applications up to 300 amps WELD CABLE CONNECTION Connect a work lead of sufficient size and length Per Table A 1 between the proper output terminal on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact To avoid interference problems with other equipment and to achieve the best possible operation route all cables directly to the work or wire feeder Avoid excessive lengths and do not coil excess cable INSTALLATION A 3 CAUTION When using an inverter type power source like the Power Waves use the largest welding electrode and work cables that are practical At least 2 0 copper wire even if the average output current would not normally require it When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor welding characteristics if undersized welding cables are used WELD CABLE SIZES Table A 2 has the copper cable sizes recommended for different currents and duty cycles Lengths stipu lated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths prim
55. TIONALITY BY WELD PROCESS Use the following tables to review how the machine functions output controls arc control and weld options for the weld modes listed in the top table ARC CONTROL ARC FORCE DESCRIPTION Soft 10 0 to Crisp 10 0 CC STICK MODES PROCESS Steel Stick Soft 7018 Steel Stick Crisp 6010 OUTPUT CONTROL KNOBS 194 Ool WFS AMPS LESS MORE AMPS AMPS On VOLTS TRIM Arc Force adjusts the short cir cuit current for a soft arc or for a forceful driving arc It helps to prevent sticking and shorting organic coated electrodes par ticularity globular transfer types such as stainless and low hydrogen Arc Force is espe cially effective for root pass on pipe with stainless electrode and helps to minimize spatter for certain electrodes and pro cedure as with low hydrogen etc OUTPUT OUTPUT OFF ON START OPTIONS No arc starting options are active for SMAW Stick welding modes END OPTIONS No arc ending options are active for SMAW Stick welding modes POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 23 OPERATION MACHINE FUNCTIONALITY BY WELD PROCESS CV GMAW FCAW NON SYNERGIC B 23 Use the following tables to review how the machine functions output controls arc control Start options and weld options for the weld modes listed in the top table CV NON SYNERGIC MODES
56. WFS voltage arc control etc immediately change the contents inside the selected procedure memory Procedure memory saving is done automatically User memories work by copying the weld procedure from one of the six memories into either the A or B procedure Weld procedures are saved into the mem ories only when the operator chooses PROCEDURE MEMORY MEMORY Lens ei m DIP SWITCH SETTINGS 59 Switch on M20122 1 P C board Memory Panel showns that Dip Switchs are in the ON position See Below Dip Switch on P C board Single Head Feeder Using Procedure Memories Procedure memories can be selected by choosing either A B procedure directly with the memory panel or by selecting GUN and using a dual proce dure gun to select between procedure A and B When selecting procedures with the gun switch A or B will flash to show which procedure is active HOLD 2 SECONDS TO SAVE PROCEDURE PRESS TO SELECT PROCEDURE POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 29 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
57. 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 WAVEFORM CONTROL anse HI Pm LO 180 WELD WFS jJ WELD MODE _ D START OPTIONS ARC CONTROL C D END OPTIONS SET IR PORT SETUP The above example shows a wire mode constant current weld modes would show Weld Amps rather than Weld WFS 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 OPERATION High Limit Memory Value d Low Limit WAVEFORM CONTROL TECHNOLOGY 2 200 IR PORT LO 18 SETUP WELD WFS WELD MODE Q O START OPTIONS ARC CONTROL O END OPTIONS Attribute B 29 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 b
58. arily for the purpose of mini mizing voltage in the welding circuit ELECTRODE LEAD Most welding applications run with the electrode being positive For those applications connect the elec trode cable between the wire feeder and the positive output stud on the power source Connect the lug at the other end of the electrode cable to the wire drive feed plate Be sure the connection to the feed plate makes tight metal to metal electrical contact The electrode cable should be sized according to the specifications given in the work cable connections Table A 1 Connect a work lead from the negative power source output stud to the work piece The work piece connection must be firm and secure especially if pulse welding is planned TABLE 2 RECOMMENDED CABLE SIZES RUBBER COVERED COPPER RATED 75 C CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES Percent Duty 0 to 50 Ft 50 to 100Ft Amperes 0 to 15 m 15 to 31m 100 to 150 Ft 150 to 200 Ft 200 to 250 Ft 31 to 48 m 48 to 61 m 61 to 76 m Tabled values are for operation at ambient temperatures of 40 C and below Applications above 40 C may require cables larger than recommended or cables rated higher than 75 C POWER FEED 10M SINGLE WIRE FEEDER LINCOLN Connect the work lead to Positive For additional Safety information regarding the elec trode and work cable set up See the standard SAFE TY INFORMATION loc
59. ated in the front of the Instruction Manuals For Electrode Connect the Polarity Electrode lead to CAUTION Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance COAXIAL WELD CABLES Coaxial welding cables are specially designed welding cables for pulse welding or STT welding Coaxial weld cables feature low inductance allowing fast changes in the weld current Regular cables have a higher inductance which may distort the pulse or STT wave shape Inductance becomes more severe as the weld cables become longer Coaxial weld cables are recommended for all pulse and STT welding especially when the total weld cable length electrode cable work cable exceeds 50 feet 7 6m A coaxial weld cable is constructed by 8 small leads wrapped around one large lead The large inner lead connects to the electrode stud on the power source and the electrode connection on the wire feeder The small leads combine together to form the work lead one end attached to the power source and the other end to the work piece See Coaxial weld Cable below Power Source Work Electrode Coaxial Weld Cable Wire Feeder Electrode Work INSTALLATION CHANGING ELECTRODE POLARITY SETTING The Power Feed 10M Single Wire Feeder is preset at the factory for Electrode Positive welding See Figure A 3 NOTE Changing this DIP Switch does not change the actual wel
60. collar and remove it from the spindle 2 Place the spool on the spindle aligning the spindle brake pin with one of the holes in the back side of the spool An indicator mark on the end of the spin dle shows the orientation of the brake holding pin Be certain the wire feeds off of the spool in the proper direction 3 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle Loading 10 to 15 Ib 4 5 6 8kg Spools A K419 spindle adapter is required for loading 2 wide spools on 2 51mm spindles Use a K419 1 spindle adapter for loading 2 1 2 64mm wide spools Squeeze release bar the retaining collar and remove it from the spindle 2 Place the spindle adapter on the spindle aligning the spindle brake pin with the hole in the adapter 3 the spool on the spindle and align the adapter brake tab with one of the holes in the back side of the spool An indicator mark on the end of the spindle shows the orientation of the brake tab Be certain the wire feeds off of the spool in the proper direction 4 Re install the retaining collar Make sure that the release bar snaps out and that the retaining collar fully engages the groove on the spindle POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 11 INSTALLATION Using K1504 1 Coil Reel FIGURE A 10 50 60 Ib 22 7 27 2 kg Coil Mounting See Figure A 10
61. ctive This is a popular choice when welding alu minum because extra heat may be needed during Start and less heat desired during Crater With 4 step trigger the welder chooses the amount of time to weld at the Start Weld and Crater settings by using the gun trigger Burnback reduces the likelihood of wire to sticking in the weld pool at the end of a weld and also prepares the end of the wire for the next arc start SEQUENCE OF OPERATION Following is the total weld sequence that the Power Feed 10M Single Wire Feeder will execute If any parameter is inactive or its time is set to zero the weld procedure immediately shifts to the next parameter in the sequence 1 PREFLOW Shielding gas begins to flow immedi ately when the gun trigger is pulled 2 STRIKE After preflow time expires the power source regulates to the start output and wire is advanced towards the work piece at the Strike WFS If an arc is not established within 1 5 sec onds the power source output and wire feed speed skips to the weld settings FIGURE B 5 OPERATION B 18 3 START The power source welds at the Start WFS and voltage until the trigger is released 4 UPSLOPE Once the trigger is released both the machine output and the wire feed speed ramp up or down to the weld settings throughout the start time The time period of ramping from the Start settings to the Weld settings is called UPSLOPE 5 WELD After Upslope the power source
62. d to stop the wire feed in the event of a fault The most common use of the circuit is with water cooled guns A flow sensor is connected to the circuit to protect the weld ing gun if the water flow is interrupted The Power Feed 10M Single Wire Feeder has two leads 570A and 570B located inside the wire drive that are electrically common If flow switch is used separate these leads and connect to normally closed flow switch terminals when water is flowing Connect the flow sensor to these two leads CHANGING THE GEAR RATIO The Power Feed 10M Single Wire Feeder wire drive may be configured for either low speed or high speed depending upon the application The wire feeders are factory assembled for low speed operation and Low speed position screw holding feed include a gear for high speed operation Ratio Solid Core plate to wire feeder Best for most GMAW and FCAW welding The low speed gear ratio 50 800 ipm 025 3 32 in 035 120 in provides the most 17 203 0 6 2 4 mm 0 9 3 0 mm force for pushing 2 wires through long guns or pulling wire through con 3 Use a 3 16 Allen wrench to remove the screws duits holding the feed plate to the wire feeder To change the gear ratio 1 Turn off power the welding power source Open the wire drive door Suitable only for small diameter 4 Use a Phillips screwdriver to remove the screw and wires operating
63. d weld 5 Stop welding by turning the Output Control 6 to OFF or by pulling away the tungsten from the work Close the gas valve on the TIG torch 8 Adjust the maximum arc amperage with the left knob on the display panel Touch the tungsten to the work piece Press the foot pedal or slide the hand amp trol a slight amount Gas will start to flow Lift the tungsten to create an arc Regulate the arc current with the foot pedal or hand amptrol Stop welding by releasing the foot pedal or hand amptrol or by pulling the tungsten away from the work Gas will continue for a short time and then shut off Adjust the maximum arc amperage with the left knob on the display panel Touch the tungsten to the work piece Press the foot pedal or slide the hand amp trol a slight amount Open the gas valve on the TIG torch Lift the tungsten to create an arc Regulate the arc current with the foot pedal or hand amptrol Stop welding by releasing the foot pedal or hand amptrol or by pulling the tungsten away from the work Close the gas valve on the TIG torch POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 28 USER MEMORIES Recall a memory with memory buttons To recall a user a memory press one of the six user memory buttons The memory is recalled when the button is released Do not hold the button for more than two seconds when recalling a user memory Recall a memory with the gun
64. de selection Arc Control adjustment Weld sequence control Preflow Time Run in WFS etc FIGURE B 3 ALUMINUM 3 64 PULSE 4043 Ar E IR PORT WELD MODE START OPTIONS ARC CONTROL END options of DS 3 MODE SELECT PANEL 4 MSP4 DESCRIPTION IR Infrared Port Weld Mode Number Weld Wire Type Wire Size Weld Mode Description Status LED Lights Weld Mode Arc Control Selection Pushbutton Weld Mode or Arc Control Set Adjustment Dial Knob Selection Pushbutton Start and End Options Status LED Lights Start End Options Through the use of alphanumeric displays the MSP4 provides standard text messages designed to enhance the user s understanding of the machine s operation as well as provide advanced capabilities The panel provides Clear identification of the selected weld mode e Identification of weld modes not listed on the preprinted weld mode list label Control of up to four wave controls arc controls e Weld mode specific wave control name display Peak Background Pinch etc Unit values are displayed Amps in min etc User friendly machine setup and configuration OPERATION B 7 Limit setting for restricting the operators range of control Lockout to prevent unauthorized changes to machine configuration Additionally the MSP4 includes an infrared IR port for wireless communication and con
65. ding polarity The actual welding polarity is changed by reversing the welding cables at the power source output studs This DIP Switch setting must coincide with the polarity you are setting up to weld with for the feeder to oper ate correctly Operating the Power Feed 10M Single Wire Feeder with the DIP switch in the wrong position will cause very erratic weld characteristics NEGATIVE ELECTRODE POLARITY This options allows for the setting of negative polarity sensing when a negative polarity welding process is performed When negative electrode polarity is required such as in some Innershield applications reverse the output connections at the power source electrode cable to the negative stud and work cable to the positive stud When operating with electrode polarity negative the Power Feed 10M Single Wire Feeder must be set to recognize this set up See Figure A 3 To change the electrode polarity DIP Switch setting A WARNING Do not touch electrically live parts or electrodes with your skin or wet clothing e e Insulate yourself from work and ground e Always wear dry insulating gloves 1 Turn off power at the welding power source 2 Remove the rear access panel on the wire drive 3 Locate the DIP switches on the Wire Drive Board 4 Set DIP switch 7 to the desired polarity 5 Reinstall the rear access panel and restore power POWER FEED 10M SINGLE WIRE FEEDER LI
66. e themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 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 keep 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 5 b 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 5 c 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 phosg
67. e background current for a soft arc good for out of position welding FIGURE B 7b Arc Control 10 0 Arc Control OFF Arc Control 10 0 Low Frequency Wide Medium Frequency and Width High Frequency Focused POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 21 ALUMINUM SYNERGIC GMAW P PULSED MIG AND GMAW PP PULSE ON PULSE WELDING The Power Feed 10M Single Wire Feeder and Power Wave welding power source combine to readily produce top quality aluminum welds with excellent appearance little spatter and good bead shape Push pull guns are available for consistent feeding when welding a long distance away from the wire feeder Pulse on Pulse Welding The Power Wave system offers both traditional pulse and Pulse on Pulse Pulse on Pulse GMAW PP is an exclusive waveform for aluminum welding Use it to make welds with a stacked dime appearance similar to GTAW welds FIGURE B 7c The pulsing frequency is adjustable Changing the fre quency modulation or arc control of the waveform changes the ripple spacing Faster travel speeds may be achieved by using higher values of frequency mod ulation FIGURE B 7d Frequency Modulation 10 Wide weld and ripple spacing slow travel speed OPERATION B 21 FIGURE B 7e tt Frequency Modulation 10 Narrow weld and ripple spacing fast travel speed POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 22 CC STICK OPERATION B 22 MACHINE FUNC
68. e input power See the power source service Manual The power source input power Capacitor bank A overvolt may be wired incorrectly Verify age the power source reconnect panel wiring matches the input power See the power source service Manual The power source input power may be wired incorrectly Verify Capacitor bank B overvolt the power source reconnect panel age wiring matches the input power Manual misadjustment have been checked and the problem persists Contact The power source has exceeded your local Lincoln Authorized the output current limits Adjust Field Service Facility the welding procedure to reduce Long term secondary over the current draw The welding current procedure may exceed the capac ity of the power source See the power source service Manual Verify the power source reconnect panel wiring matches the input power Capacitors are out of bal ance 2 See the power source service Manual A high level of output current long average has caused an overload This happens when the wrong Output stud is used on an STT machine or if there is a missing input phase When this fault occurs the machine output will be shut off CAUTION If any reason you 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 proce
69. e is one 20 gauge twist ed pair for network communications This pair has an impedance of approximately 120 ohms and a propa gation delay per foot of less than 2 1 nanoseconds There are two 12 gauge conductors that are used to supply the 40 VDC to the network The fifth wire is 18 gauge and is used as an electrode sense lead AVAILABLE CONTROL CABLE K1543 Control cable only Available in lengths of 8 2 4m 16 4 9m 25 7 6m 50 15 2m and 100 30 5m POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 6 WIRE DRIVE SYSTEMS Drive Roll Kits are designed to feed specific types and wire sizes The Power Feed 10M Single Wire Feeder does not include these Drive Roll Kits with this Wire Drive but are available for ordering from the fol lowing tables Drive Roll Kits Steel Wires Includes 4 Smooth V groove drive rolls and an inner wire guide KP1505 030S KP1505 035S KP1505 045S KP1505 052S KP1505 1 16S 023 030 0 6 0 8mm 035 0 9mm 045 1 2mm 052 1 4mm 1 16 1 6mm Drive Roll Kits Cored Wires Includes 4 Knurled drive rolls and an inner wire guide KP1505 035C KP1505 045C KP1505 052C KP1505 1 16C 030 035 0 8 0 9mm 040 045 1 0 1 2mm 052 1 4mm Drive Roll Kits Steel or Cored Wires Includes 4 Knurled drive rolls and an inner wire guide KP1505 068 KP1505 5 64 KP1505 3 32 KP1505 7 64 KP1505 120 068 072 1 8mm 5 64 2 0mm 3 32 2 4mm 7 64 2 8mm 120 3 2m
70. e switch is disabled To operate 1 Select GUN on the memory panel 2 Start the weld by pulling the gun trigger The system will weld with procedure A settings 3 While welding quickly release then pull the gun trigger once The system will switch to procedure B settings Repeat to switch back to procedure A settings The procedure can be changed as many times as needed during the weld Release the trigger to stop weld ing The system will automatically return to procedure A settings Integral TrigProc When using a Magnum DS dual schedule gun or similar that incorpo rates a procedure switch in the gun trigger mechanism While welding in 2 step machine operation is identical to the External Switch selection When welding in 4 step additional logic prevents procedure A from being re selected when the trigger is released at step 2 of the 4 step weld sequence The machine will always operate in 2 step if a weld is made exclusive ly in procedure A regardless of the 2 4 step switch position this is intended to simplify tack welding when using a dual schedule gun in 4 step Stall Factor Adjustment Allows the adjustment of the stall factor in Push Pull operation The stall factor controls the stall torque of the push motor when using a push pull gun The wire feeder is factory set to not stall unless there is a large resistance to feeding wire The stall factor can be reduced to stall more easily and possibly prevent bird nesting Howev
71. e 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 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 Y
72. ed POWER FEED 10M SINGLE WIRE FEEDER LINCOLN Short term secondary over current TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS SYMPTOMS Main CPU problem Voltage sense loss Motor overload long term Motor overload short term Err 95 Spool gun or pull gun motor overload 263 No usable weld modes POSSIBLE CAUSE ARCLINK SYSTEM ERROR CODES the power source is wired correct ly See the power source service Manual The system detected that one of the voltage sense lead cables was disconnected from the weld ing circuit during a weld The wire drive motor has over heated Check that the electrode slides easily through the gun and cable 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 The drive motor in the spool gun or push pull gun is drawing too much current The power source does not have any welding programs loaded Required configuration could not be found RECOMMENDED COURSE OF ACTION 1 Verify the ground connection to 1 The main processor in the system did not respond to another processor within the allotted time Reflash system with latest soft ware Replace circuit board Verfy that leads 67 and 21 is enabled and connected See enhanced schematic Remove ti
73. em ory number For example to recall memory 3 quickly pull and release the trigger 3 times To recall memory 1 quickly pull and release the trigger the number of user memories plus 1 Memories cannot be recalled while the system is welding A memory panel must be installed in order to use this feature Disabled The gun trigger cannot be used to recall user memories default Enabled The gun trigger can be used to recall user memories POWER FEED 10M SINGLE WIRE FEEDER LINCOLN B 12 OPERATION B 12 USER DEFINED PARAMETERS Procedure Change Method Selects how remote procedure selection A B will be made The selected procedure can be changed locally at the user interface by pressing the A Gun B button The following methods can be used to remotely change the selected procedure Use an external switch wired to the procedure select input Quickly releasing and re pulling the gun trigger Using a dual schedule gun which incorporates a procedure select switch in the trigger mecha nism pulling the trigger more than half way changes the procedure from A to B The possible values for this parameter are External Switch Procedure selection may only be performed at the memory panel or external switch e g K683 Quick Trigger The selected procedure can be changed remotely by releasing and re pulling the trigger quickly while welding This feature is disabled in 4 Step trigger mode The external procedur
74. ench Incoming Bushing Lincoln Conduit Includes Incoming bushing 1 16 1 8 and hex key wrench K1733 1 Wire Straightener Includes Wire Straightener K870 1 Foot Amptrol Includes F oot Amptrol Hand Amptrol LA 9 17 LW20 Includes Hand Amptrol LA 9 17 LW20 Hand Amptrol LA 26 LW 18 Includes Hand Amptrol LA 26 LW 18 POWER FEED 10M SINGLE WIRE FEEDER LINCOLN ACCESSORIES Includes Spindle Assemble Spindle Adapter for Readi Reels with locking clip and 2 ID spools up to 60 Ib Includes Spindle Adapter made from 2 coil retainers Electrode not included Spindle Adapter for mounting 14 lb Innershield Coils on 2 spindles Spindle Adapter for mounting 8 Includes Spindle Adapter dia spools on 2 spindles K1504 1 K1634 1 Readi Reel Adapter for mounting 23 30 Ib reels to 2 spindles Readi Reel Adapter for mounting 50 60 Ib reels to 2 spindles Coil Adapter for mounting 50 60 Ib coils to 2 spindles Plastic Wire Cover for 30 44 Ib Wire packages Plastic Wire Cover for up to 60 Ib Wire packages Water Connection Kit Includes Readi Reel spool adapter Spool of electrode not included Includes Readi Reel spool adapter Spool of electrode not included Includes 50 60 Ib coil adapter Includes Cover backing plate wire conduit incoming bushing for 025 1 16 wire incoming bushing for 1 16 1 8 wire thumb screw mounting ha
75. ene a highly toxic gas and other irritating prod ucts 5 d 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 5 e Read and understand the manufacturer s instructions for this 5 4 LINCOLN 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 WELDING and CUTTING SPARKS can 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 Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums
76. ent 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 E SAFETY i PRECAUTIONS DE 5 Toujours porter des lunettes de s curit dans la zone de 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 po
77. er low stall factors can cause motor stalling during normal welding conditions which results in the wire burning back to the tip or rapid tack welds If you are experiencing bird nests check for other feeding problems before adjusting the stall factor The default value for the stall factor is 75 with a range of 5 to 100 POWER FEED 10M SINGLE WIRE FEEDER LINCOLN ee OPERATION B 13 USER DEFINED PARAMETERS 7 Gun Offset Adjustment Range 30 to 30 default 0 Adjusts the wire feed speed calibration of the pull motor of a push pull gun This should only be performed when other possible corrections do not solve any push pull feeding problems An rpm meter is required to perform the pull gun motor offset calibration To perform the calibration procedure do the following e Release the pressure arm on both the pull and push wire drives Set the wire feed speed to 200 ipm Remove wire from the pull wire drive Hold an rpm meter to the drive roll in the pull gun Pull the trigger on the push pull gun Measure the rpm of the pull motor The rpm should be between 115 and 125 rpm If neces Sary decrease the calibration setting to slow the pull motor or increase the calibration setting to speed up the motor P 8 TIG Gas Control Allows control over which gas solenoid actuates while TIG welding Valve manual No MIG solenoid will actuate while TIG welding gas flow is manually con trolled by an external val
78. er s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility 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
79. etely remove the socket head cap screw 6 Remove the outer wire guide and push the gun bush ing out of the wire drive Because of the precision fit light tapping may be required to remove the gun bush ing 7 Disconnect the shielding gas hose from the gun bush ing if required 8 Connect the shielding gas hose to the new gun bush ing if required 9 Rotate the gun bushing until the thumb screw hole aligns with the thumb screw hole in the feed plate Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned Note Some gun bushings do not require the use of the thumb screw 10 Tighten the socket head cap screw 11 Insert the welding gun into the gun bushing and tight en the thumb screw Gun Receiver Bushing K1500 1 For use With K466 1 Lincoln gun connectors Innershield and Subarc guns K466 2 K466 10 Lincoln gun connectors Magnum 200 300 400 guns and compatible with Tweco 4 K1637 7 Lincoln gun connectors Magnum 550 guns and compatible with Tweco 5 K466 3 Lincoln gun connectors compatible with Miller guns Compatible with Oxo guns K489 7 Lincoln Fast Mate guns POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 8 WELDING GUNS TORCHES AND ACCES SORIES GUN RECEIVER BUSHING The Power Feed 10M Single Wire Feeder comes with a K1500 2 gun receiver bushing for use with the Magnum gun with a K466 10 connector kit which
80. figuration using a Palm OS based hand held computer and a simplified control layout LAYOUT CONTROLS SEE FIGURE B 3 The MSP4 panel controls Items 7 and 9 set consist of an encoder knob Item 8 and two push buttons The encoder is primarily used to change the value of the selected attribute The left pushbutton Item 7 is used to toggle between Weld Mode selection and any active Arc Controls a k a wave controls The choices of wave controls varies by weld mode For example weld mode 31 has one wave control Pinch Weld mode 110 has three wave controls Peak Current Background Current and Tailout If the selected weld mode has no wave controls pressing the left pushbutton will have no affect If the selected weld mode uses one or more wave controls pressing the left pushbutton will sequence the selection from weld mode gt wave con trol 1 if active gt wave control 2 if active gt wave control 3 if active gt wave control 4 if active then back to weld mode The right pushbutton Item 9 is used to select attribut es that affect the available weld parameters such as preflow time burnback time etc Since most users will require infrequent access to these attributes they are separate from weld mode selection and wave control adjustment LAYOUT DIGITAL DISPLAY The MSP4 display consists of a large 4 digit 7 seg ment LED display two 8 character alphanumeric LED displays and one 16 character
81. g ing on contact with hot engine parts and current creates EMF fields around welding cables and igniting Do not spill fuel when filling tank If welding machines fuel is spilled wipe it up and not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment 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 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running M 1 9 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 LINCOLN effects which are now not known All welders should use the following procedures in order to minimize exposure
82. ge of an open or short in the primary Right side facing machine side of the machine Thermal error Indicates over temperature Usually accompanied by Thermal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine Softstart error Capacitor precharge failed Usually accompanied by codes 32 35 Secondary overcurrent error The secondary weld current limit has been exceeded When this occurs the machine output will phase back to 100 amps typically resulting in a condition referred to as noodle welding NOTE For the Power Wave 455 R the secondary limit is 570 amps for the standard stud and 325 amps for the STT stud and all single phase operation Capacitor delta error The maximum voltage difference between the main capacitors has been exceeded May be accompa nied by errors 32 35 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 10M SINGLE WIRE FEEDER LINCOLN 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10675 and above ERROR CODES FOR THE POWER WAVE 455 The following is a list of possible error codes that the Power Feed 10M Dual Wire Feeder can output via the dis play on this user inte
83. ght bends from the gun and cable Check that the spindle brake is not too tight Verify a high quality electrode is being used Wait for the error to reset and the motor to cool approximately 1 minute Verify that the gears are free of debris and dirt Check spool gun brake or feeding for binding Replace spool gun circuit board Make sure the status of all devices is conected correctly to the machine Reflash system software CAUTION If for any reason you 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 10M SINGLE WIRE FEEDER LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION The feeder doesn t power up no 1 display no cold feed OUTPUT PROBLEMS The Power Feed 10M Single 1 Wire Feeder power switch is OFF Turn the Power Feed 10M Single Wire Feeder power switch ON The Power Wave power source is OFF Turn ON the Power Wave power source The circuit breaker for the wire feeder on power source have 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
84. gt gt 189 969 12 LIST TINd HsNd soo 32 9989 0 9 1 9 L 289 10048 2g svo 93908594 525 HONI 5 p LZZLL 91211 98011 HOS AYAH Q334 ATONIS WO A334 H3MOd IWVHOVIG ONIHIM F 1 POWER FEED 10M SINGLE WIRE FEEDER LINCOLN E 2 97 S Lu DIAGRAMS F 2 Jequunu epoo jueuudinbe y BAIN eui eu 2 s y sjoued einsojoue y jo euo uo paysed si epoo 104 eu siu jou j L 6 vv5 orar var soreer ir amp E zarar sr 0 d 40 IN3NOdWOO WOH3 Q3M3IA 3ON3nO3S ALIAVO 31IHM M ama n Moviga g SNIGOD 30705 Qv31 4 813 Had SIOSNAS 19914419573 NOILVWHOSNI TVH3N39 xog TOYLNOD 310v1d303u 1
85. is occurs while welding the sta ject tus LED should be flashing red on the object that lost heart beat Otherwise look for any nodes that are flashing green This indicates they have not been recognized and there is a power source problem see power source trouble shooting section If the status LED is either flashing or solid red there may be a problem with continuity in the com munication lines Check the lines for continuity in the cable and harness ing refer to wiring diagram EEPROM error Parameter recaled at power up was out of range Rotate encoder knob to reset Check all settings before procedding to weld If this condition persists the replac the CB mother PC board ee If any reason you do not understand the test 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 10M SINGLE WIRE FEEDER LINCOLN 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10675 and above ERROR CODES FOR THE POWER WAVE 455 The following is a list of possible error codes that the Power Feed 10M Dual Wire Feeder can output via the dis play on this user interface Note For any Err listed below write down the error number for reference and try cycling po
86. ln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 5 TROUBLESHOOTING 5 Observe Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10675 and above ERROR CODES FOR THE POWER WAVE 455 As a troubleshooter aid error code information will now persist on the user interface displays even after the fault is cleared When a fault occurs that the user interface needs to display welding will be inhibited for 5 seconds If the fault has cleared the error code information can then be removed from the displays by pressing the Reset button by changing a user interface control or by starting a new weld The following is a list of possible error codes that the Power Feed 10M Dual Wire Feeder can output via the dis play on this user interface Note For any Err listed below write down the error number for reference and try cycling power to see if the error clears itself If not refer to the What to Do column for the given Err PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Capacitor A under voltage Excess voltage on the main capaci Left side facing machine tors May be caused by improper input configuration When accompanied by an undervolt age error on the same side it indi cates no capacitor voltage present on that side and is usually the result Capacitor B under volta
87. lost The trigger can be used to hot feed the wire default If a value is set the machine output will shut off if an arc is not estab lished within the specified amount of time after the trigger is pulled or if the trigger remains pulled after an arc is lost This is disabled while welding in Stick TIG or Gouge To prevent nuisance errors set Arc Start Loss Error Time to an appropriate value after considering all welding parameters run in wire feed speed weld wire feed speed electrical stick out etc To prevent subsequent changes to Arc Start Loss Error Time the setup menu should be locked out by setting Preference Lock Yes using the Power Wave Manager software Sense From Studs Use this option for diagnostic purposes only When power is cycled this option is automatically reset to False False Voltage sensing is determined by the DIP switch configuration and the selected weld mode default True Voltage sensing is forced to studs regardless of the DIP switch configuration and selected weld mode Sense Leads Selection Used in place of DIP switches for configuration of the work and electrode sense leads This option will only appear in the list if the power source has a hardware selection option 67 pos polarity 2 An electrode sense lead is connected using positive polarity This is used by most GMAW welding procedures 67 neg polarity An electrode sense lead is connected using negative polarity This is used by
88. m Drive Roll Kits Hardfacing Wires Includes 2 Knurled drive rolls 2 Smooth V groove drive rolls and an inner wire guide KP1505 7 64C Drive Roll Kits Aluminum Wire Includes 4 polished U groove drive rolls outer wire guide and an inner wire guide KP1507 035A KP1507 040A KP1507 3 64A KP1507 1 16A KP1507 3 32A 035 0 9 mm 040 1 0mm 3 64 1 2mm 1 16 1 6mm 3 32 2 4mm INSTALLATION A 6 CHANGING DRIVE ROLLS AND WIRE GUIDES FIGURE A 4 MZ CG WIRE DRIVE DOOR OPEN DESCRIPTION Inner Wire Guide Drive Rolls I aa Outer Wire Guide ITEM 2 3 To change drive rolls and wire guides 1 Turn off power at the welding power source 2 Open wire drive door 3 Remove the outer wire guide Item 3 4 Remove the 4 drive rolls Item 2 by pulling them straight off of the drive hub Rock the upper drive rolls back for ease of removal 5 Remove the inner wire guide Item 1 6 Insert the new inner wire guide Item 1 over the locating pins of the feed plate 7 Install each drive roll by pushing it onto the hub until it fully seats 8 Install the outer wire guide 9 Swing the upper drive rolls down and close the wire drive door POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 7 DRIVE ROLL PRESSURE SETTING The Power Feed 10M Single Wire Feeder is factory set with the pressure indicator approximately 2 The best drive roll press
89. n to the CO cylin der Attach one end of the inlet hose to the outlet fitting of the flow regulator Attach the other end to the welding system shielding gas inlet Tighten the union nuts with a wrench Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting Spring pressure is released Standing to one side open the cylinder valve slowly a fraction of a turn When the cylinder pressure gage stops moving open the valve fully The flow regulator is adjustable Adjust it to the flow rate recommended for the procedure and process being used before making a weld POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 14 INSTALLATION EXAMPLES OF CONNECTING AN Robotic Semi Automatic System ARCLINK POWER WAVE SYSTEM Use the bench feeder for offline welding ArcLink Power Wave products may be configured in many different ways The flexible system allows multi ple wire feeders to be connected to the same power source The diagrams represent some of the common methods for connecting ArcLink Products Important Bench model wire feeders cannot be sepa rated into a separate control box and wire drive for a boom system Common ArcLink Systems The following Power Wave systems may all be assembled without any changes to the equipment DIP Switches Basic Semi Automatic System Great for general fabrication Shown with K2230 1 Power Feed 10M Single Wire Feede
90. nd current to increase the heat input Displays the preset CP value from 0 to 20 The Power mode is best for thin sheet metal and aluminum applications Nonsynergic Power DURING WELDING Weld Process Volts Trim Display All Processes Displays Actual Average Arc Voltage AFTER WELDING Vol Trim Display After welding the meter holds the actual average arc voltage for 5 seconds Processes During this time the display flashes to indicate the wire feeder is in the Hold period Output adjustment while in the Hold period results in the prior to oper ation characteristics described above SYNERGIC CV VOLTAGE DISPLAY Synergic CV programs feature an ideal voltage best suited for most procedures Use this voltage as a starting point for the weld procedure and adjust if needed for personal preferences The voltage is calibrated to 2 over a range of 10 to 45 volts When the voltage knob is rotated the display will show an upper or lower bar indicating if the voltage is above or below the ideal voltage Preset voltage above ideal voltage upper bar displayed Preset voltage at ideal voltage no bar displayed Preset voltage below ideal voltage lower bar displayed POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 7 OVERVIEW The MSP4 is the standard mode select panel for the Power Feed 10M Single Wire Feeder wire feeders The MSP4 is capable of Weld mo
91. nking during a reset and indicates the power source is identifying each component in the system This is nor mal for the first 10 seconds after power up or if the system configura tion is changed during operation Non recoverable system fault If the power source or wire feeder status LED is flashing any combination of red and green errors 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 section Non recoverable hardware fault Generally indicates a problem with the cables connecting the wire feeder to the power source Not applicable 2 DIGITAL METERS AND OUTPUT ENCODER KNOBS See Figure B 2 Blinking red The primary weld procedure settings are controlled and displayed using digital meters and output encoder knobs located at the top of the Power Feed 10M Single Wire Feeder control panel FIGURE B 2 A WIRE FEED SPEED AMMETER DISPLAY AND OUTPUT KNOB A B j 400 263 WFS AMPS VOLTS TRIM This meter displays either the wire feed speed or cur rent value Amps depending upon welding process Mode being used
92. ns tesis tet episc suce texte seis B 1 Graphic vire ERR B 1 Definitions of Welding Modes B 2 Common Welding Abbreviations B 2 EM 2 Recommended Processes ii B 2 B 3 Fedquir d EQquiptment ee nee B 3 Front Panel Controls and Connections sssrini iieii iandien inadai idiin B 5 LED e B 5 2 Digital Meters and Output Encoder Knobs sssseeee B 5 B 7 A Wire Feed Speed Ammeter display and output B 5 B Volts Trim display and Output Knob B 6 Synergic CV Voltage Display ss B 6 Em B 7 3 Mode Select Panel 4 MSP4 nic an a e iia cu Layout RE La yout Digital SEQUENCE 2 62 nre dev Changing Weld MOGd6s accede ieee Heed ee ee Changing Arc Wave Control ss Changing Weld Sequence Behavior Infrared IR em LOCKOUUSOCUMITY LEER Machine Setup user preferences sesssssseeeenenenen nennen Accessing the Machine Setup Menu Setup Ment SNT 4 Cold Feed Gas P
93. o check the continuity of all five leads from one end to the See power source service other The control board in the PW Manual 455 may be faulty The power source has issued a shutdown command Verify the power source is operating proper ly Status light steady green 9ee Err 006 in this chart Check control cable for loose or broken leads See power source service Manual ARCLINK SYSTEM ERROR CODES Primary overcurrent The power source has exceeded input current limits Adjust the welding procedure to reduce the current draw The welding proce dure may exceed the capacity of the power source See the power source service Manual Err 32 Capacitor bank A 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 service 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 10M SINGLE WIRE FEEDER LINCOLN 9 TROUBLESHOOTING E 9 Observe all Safety Guidelines detailed throughout this manual 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 th
94. osition work GMAW SMAW GMAW Pulse GTAW Touch Start TIG only GMAW STT CAG FCAW POWER FEED 10M SINGLE WIRE FEEDER LINCOLN B 3 OPERATION PROCESS LIMITATIONS The Power Feed 10M Single Wire Feeder is not suitable for SAW GTAW with HF Not all weld modes or processes described in this manual are avail able on all Power Wave power sources REQUIRED EQUIPMENT Lincoln s Power Feed 10M Single Wire Feeder is designed for use with the Power Wave family of power sources These include Power Wave 355 Power Wave 455M Power Wave 455 Power Wave 455M STT Power Feed 455 STT Power Wave 455M STT e Power Wave 455M Power Wave 655 ADDITIONAL REQUIRED EQUIPMENT Drive Roll Kits Control Cables Gun and Cable Assembly Weld Wire Shielding gas Work Cable and Clamp EQUIPMENT LIMITATIONS The Power Feed 10M Single Wire Feeder does not operate with the Power Wave 450 The Power Feed 10M Single Wire Feeder does not operate with any analog based power sources CV xxx machines DC xxx machines etc The Memory Panel is required to set procedure limits The Boom model does not support push pull guns or GTAW welding A push pull gun and foot amptrol may not be plugged into the Power Feed 10M Single Wire Feeder at the same time POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 4 OPERATION B 4 FRONT PANEL CONTROLS AND CONNECTION
95. pent 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 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 RUBUS PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER ux TRANSFORMATEUR ET a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR 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 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc 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 cha
96. power source The Power Feed 10M Single Wire Feeder system has the ability to connect multiple wire feeders to one power source use the same power source to weld in two different locations not simultaneously or load a different electrode on each feeder to eliminate change over time The powerful four roll wire drive system sets the industry standard for ease of use Its patented design allows for tool less change out of wire guides and drive rolls greatly reducing set up time General Functional Description The Power Feed 10M Single Wire Feeder is highly versatile wire feeder with easy to use fea tures that make it easy for the operator to adjust the arc for specific preferences The new MSP4 panel clearly displays key welding information Use the MSP4 panel to quickly adjust weld settings arc starting parameters arc end para meters and set up variables The Power Feed 10M Single Wire Feeder wire feeder is provided with an infrared red IR port Transferring welding settings from one wire feeder to another is accomplished with a common palm computer When the Power Feed 10M Single Wire Feeder is coupled to a Power Wave welding power source the result is a welding system with absolutely supe rior arc performance RECOMMENDED PROCESSES The Power Feed 10M Single Wire Feeder is well suited for all MIG welding processes giving premium arc performance especially with unusual alloys and out of p
97. r 2203 1 Power Wave 455M STT Boom Semi Automatic System Often used when making large weldments Shown with K2314 1 Power Feed 10M Single Wire Feeder Boom includes wire drive and control box K2203 1 Power Wave 455M STT Shown with K2230 1 Power Feed 10M Single Wire Feeder K1780 2 PF 10 R K2203 1 Power Wave 455M STT K2205 1 Wire Drive Module Multiple Wire Feeder System Load one feeder with solid wire the other with flux cored Great for pipeline work Shown with e K2429 1 ArcLink T Cable Connector K2196 1 Power Feed 15M K2203 1 Power Wave 455M STT ArcLink Systems Many other ArcLink systems may be assembled besides those shown in this manual The majority will self configure If an assembled system flashes the sta tus light green rapidly on all components contact the Lincoln Electric Company for further assistance Current Power Feed 10M models that will not self configure K2316 1 Power Feed 10M Dual Boom These configurations will require Dip Switches to be set See the power source instruction manual on how to disable self configuration POWER FEED 10M SINGLE WIRE FEEDER LINCOLN AUS INSTALLATION A 15 BOOM CONFIGURATION BENCH MODEL FEATURES SPINDLE ASSEMBLY A ROLL BAR CONTROL BOX
98. r than OFF the END OPTIONS LED will blink synchronously with the dual display LED s indicating that crater wire feed speed and voltage trim now can be set to values different from those used while welding INFRARED IR CONTROL The MSP4 interface includes an infrared transceiver This allows wireless machine configuration using a Palm OS based hand held computer A proprietary Palm OS application Weld Manager was developed for this pur pose Contact Lincoln Electric for more information on this feature LOCKOUT SECURITY The MSP4 can be optionally configured to prevent the welder from changing selected user interface controls By default all user interface controls can be changed Weld Manager software for Palm OS or PC must be used to lock or unlock user unterface controls and to set a pass code POWER FEED 10M SINGLE WIRE FEEDER LINCOLN B 9 OPERATION LIMIT SETTING The MSP4 can be optionally configured to limit the operator s range of control of any weld parameter weld WFS arc control etc Limits are only available with the Dual Procedure Memory Panel MACHINE SETUP USER PREFERENCES The MSP4 can be used to configure and troubleshoot the machine ACCESSING THE MACHINE SETUP MENU To access the Machine Setup menu press both MSP4 push buttons simultaneously The MSP4 7 segment display will dis play the first user preference P O and the SETUP LED will illuminate Pressing the left MSP4 pu
99. rce refer to wiring diagram Refer to Power source trouble shooting section for additional information If all these avenues fail replace CB mother PC board CAUTIONN If for any reason you do not understand the test ee CUNO 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 10M SINGLE WIRE FEEDER LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10555 and below Note For any Err listed below write down the error number for refference and try cycling power to see if the error Clears itself If not refer to what the What to Do column for the given Err PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Display shows any An attempt was made to reprogram Check for potential electrical HF a CB or feed head but the program noise generators in the area Try did not verify removing the noise source and pro gramming again If the Err 020 still occurs either replace the EEPROM chop s in teh board being reprogammed or replace the whole PC board being reprogrammed The Power Source issued a shut See what to Do on Err 006 down command for some reason No Heart beat response from the See what to Do on Err 006 PS No Heart beat response from an If th
100. rdware and hex key Includes 2 hoses 4 quick dis connect fittings hose clamps and mounting hardware POWER FEED 10M SINGLE WIRE FEEDER LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger 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 maintenance work Observe all additional Safety Guidelines detailed throughout this manual ROUTINE MAINTENANCE Check weld cables 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 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 10
101. rface Note For any Err listed below write down the error number for reference and try cycling power to see if the error Clears itself If not refer to the What to Do column for the given Err PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Single phase error Indicates machine is running on sin gle phase input power Usually caused by the loss of the middle leg L2 Error codes that contain three or four digits are defined as fatal errors These codes generally indicate inter nal errors on the Power Source Control Board If cycling the input power on the machine does not clear the error try reloading the operating system If this fails replace the con trol board 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 10M SINGLE WIRE FEEDER LINCOLN E 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10555 and below Note For any Err listed below write down the error number for refference and try cycling power to see if the error Clears itself If not refer to what the What to Do column for the given Err PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Display shows any of the following
102. s detailed throughout this manual Error Codes for the Power Wave 455 Code 10555 and below Note For any Err listed below write down the error number for refference and try cycling power to see if the error Clears itself If not refer to what the What to Do column for the given Err PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Disney shows any one nee LLL More than 1 CB with the same Make sure the group dip switch set group number ting is unique for each CB Too many objects in group A given group can only support up to 7 objects Remove any objects over 7 from the group either by changing the group dip switch set tings or physically disconnecting any objects over 7 in the group More than 1 object of the same Adjust the dip switch setting to make eqipment type with the same group either the group or feed head and feed head unique for all oobjects of the same equipment type A feed head has its feed head dip The appropriate feed head is 1 switches set to zero in a group with through 7 Check the dip switch set more than one object ting chart in INSTALLATION section and set the switches to make the Feed head ID non zero Did not receive a recognition com Check to see if the status light is not mand from the power source solid green on the power source refer to status light states in OPER ATION section if not Also check continuity in the communication lines from CB to Power Sou
103. scribed in later sections 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 displays will show a hatch pattern 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 dis play will show Initializing while waiting for the Weld Sequencer to announce bus available The MSP4 alphanumeric displays will then display the name of the weld table loaded in the power source while the user interface prepares the machine for operation After all initialization is complete the MSP4 will dis play the weld mode information for the mode number that was selected when the machine was last pow ered down CHANGING WELD MODES To select a weld mode press the left MSP4 pushbut ton until the WELD MODE LED is illuminated Turn the MSP4 encoder until the desired weld mode num ber is displayed As the MSP4 encoder knob is rotat ed only the weld mode number is displayed After 1 second of encoder idle time the user interface will change to the selected weld mode and the new mode s electrode type electrode size and process information will appear CHANGING ARC WAVE CONTROL If the selected weld mode uses any of the four available wave controls users can press the left MSP4 pushbutton until the ARC CONT
104. shbutton will exit the entire Machine Setup menu while in the P O user preference Turning the MSP4 encoder knob will select other available User Preferences e To exit the User Preference Menu either rotate the MSP4 encoder until P 0 is displayed and press the left MSP4 push button or press both MSP4 push buttons simultaneously at any time POWER FEED 10M SINGLE WIRE FEEDER LINCOLN a OPERATION B 10 SET UP FEATURES MENU The Setup Menu gives access to the Setup Configuration Stored in the setup configuration are user parameters that generally only need to be set at installation The parameters are grouped as shown in the following table PARAMETER DEFINITION P 1 through P 99 Unsecured Parameters always adjustable P 100 through P 107 Diagnostic Parameters always read only SET UP FEATURES MENU See Figure B 3a 1 To access the set up menu press the Right and Left buttons of the MSP4 panel simultaneously Note that the set up menu cannot be accessed if the system is welding or if there is a fault The sta tus LED is not solid green Change the value of the blinking parameter by rotat ing the SET knob 2 After changing a parameter it is necessary to press the Right hand button to save the new setting Pressing the Left button will cancel the change 3 To exit the set up menu at any time press the Right and Left buttons of the MSP4 panel simulta neously Alternately 1 minute of inactivity will also
105. slope the power source output and the wire feed speed continue at the weld settings CRATER As soon as the trigger is released the wire feed speed and power source output ramp to the crater settings throughout the crater time The time period of ramping from the weld settings to the crater settings is called DOWNSLOPE BURNBACK After the crater time expires the wire feed speed is turned OFF and the machine output continues for the burnback time POSTFLOW Next the machine output is turned OFF and shielding gas continues until the post flow timer expires Trigger Released B urrback Time i i jek cD mm mn FIGURE 4 8 2 2 3 E Idle 1 Preflow Strike LI i i Shielding emo i 1 Ofi awe ll quiu ig i 1 i L ME NE NN Stattime I i a i 1 H i 15 secmax i Source UE aiaa donnee vi or 1 MU ENGL NUBE NE i 1 i H i i i 1 i Weld j 4 i i WFS Crater 1 Of POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 18 4 STEP TRIGGER OPERATION See Figure B 5 The 4 step trigger sequence gives the most flexibility when the Start Crater and Burnback functions are a
106. t button to back out to select another board Press the left button again to exit this option View Welding Software Information Used for viewing the Weld Set in the Power Source Press the right MSP Button to read the Weld Set version Press the left button to back out and exit this option View Ethernet IP Address Used for viewing the Ethernet Network IP address if there is an Ethernet board present in the system Press the right MSP Button to read the IP Address Press the left button to back out and exit this option The IP address cannot be changed using this option View Power Source Protocol Used for viewing the type of power source the feeder is connected to Press the right MSP Button to identify the power source as either LincNet or ArcLink Press the left button to back out and exit this option POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 16 4 COLD GAS PURGE SWITCH Cold Feed and Gas Purge are combined COLD FEED into a two position momentary toggle switch To activate Cold Feeding hold the switch in the UP position The wire drive will feed electrode but neither the power source nor the gas solenoid will be ener 5 gized Keeping the electrode and gun A electrically cold Adjust the speed of GAS PURGE cold feeding by rotating the WFS knob This feature is useful for threading the electrode through the gun While the cold feed circuit is activated adjust the wire feed speed
107. the Start Procedure to the preset Welding Procedure Start Procedure VOLTS TRIM LESS MORE TRIM TRIM END OPTIONS EFFECT RANGE FUNCTION Postflow Time Adjusts the time that shielding 0 to 25 0 seconds gas flows after the welding out put turns off The burnback time is the amount of time that the weld output continues after the wire stops feeding It prevents the wire from sticking in the puddle and prepares the end of the wire for the next arc start Crater Procedure controls the WFS and volts for a specified time at the end of the weld after the trigger is released During the Crater time the machine will ramp up or down from the Weld Procedure to the Crater Procedure Burnback 0 to 25 Seconds Crater Procedure Adjusts the time welding will continue even if tigger is still pulled This option has no effect in 4 Step Trigger Mode Spot Timer 0 to 120 0 Seconds POWER FEED 10M SINGLE WIRE FEEDER LINCOLN B 26 OPERATION B 26 MACHINE FUNCTIONALITY BY WELD PROCESS STT AND STT II SYNERGIC Use the following tables to review how the machine functions output controls arc control Start options and weld options for the weld modes listed in the top table STT AND STT II MODES MATERIAL PROCESS De WIRE SIZE 0 035 0 045 0 052 STEEL STEFL STTI Arco STAINLESS OUTPUT CONTROL KNOBS There is no Voltage control when STT welding START OPTIONS PREFLOW TIME
108. the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger 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 maintenance work Observe all additional Safety Guidelines detailed throughout this manual CAUTION If any reason you 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 10M SINGLE WIRE FEEDER LINCOLN 2 TROUBLESHOOTING E 2 Observe all Safety Guideline
109. the wire drive unit is kept at minimum 2 The electrode is hot when the gun trigger is pressed and must be insulated from the boom and structure If more than one wire feed unit shares the same boom and are not sharing the some power source output stud their wire and reels must be insulated from each other as well as insulated from their mounting structure O POWER FEED 10M SINGLE WIRE FEEDER LINCOLN INSTALLATION SHIELDING GAS CONNECTION NOTE Gas supply pressure must be regulated to a maximum of 80 psi 5 5 bar Install the shielding gas supply as follows 1 2 Secure the cylinder to prevent it from falling Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve outlet Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench Note if connecting to 10096 CO cylinder insert regulator adapter between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seated for connectio
110. uence The 2 Step 4 Step trigger has no effect when welding with SMAW or CAG procedures POWER FEED 10M SINGLE WIRE FEEDER LINCOLN 17 2 STEP TRIGGER OPERATION See Figure B 4 Sometimes it is advantageous to set specific arc start crater and arc ending parameters for the ideal weld Many times when welding aluminum crater control is necessary to make a good weld This is done by set ting Start Crater and Burnback functions to desired values SEQUENCE OF OPERATION Following is the total weld sequence that the Power Feed 10M Single Wire Feeder will execute If any parameter is inactive or its time is set to zero the weld procedure immediately shifts to the next parameter in the sequence 1 PREFLOW Shielding gas begins to flow immedi ately when the gun trigger is pulled 2 STRIKE After preflow time expires the power source regulates to the start output and wire is advanced towards the work piece at the Strike WFS f an arc is not established within 1 5 sec onds the power source output and wire feed speed skips to the weld settings OPERATION N Weld mme me EET 1 17 UPSLOPE Once wire touches the work and arc is established both the machine output and the wire feed speed ramp to the weld settings through out the start time The time period of ramping from the start settings to the weld settings is called UPS LOPE WELD After up
111. ur le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines 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 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 c bles jusqu ce qu ils se rom
112. ure varies with wire type wire sur face lubrication and hardness Too much pressure could cause birdnesting but too little pressure could cause slippage Set the drive roll pressure by 1 Press the end of the gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds 2 If the wire birdnests or jams the drive roll pres sure is too high Reduce the pressure by one turn of the knob run new wire through the gun and repeat step 1 3 If the only result is slippage disconnect the gun and pull the gun cable forward about 6 150mm There should be a slight waviness in the exposed wire If there is no waviness increase the pressure setting one turn reconnect the gun and repeat the above steps CHANGING THE GUN RECEIVER BUSHING Gun receiver bushings make it easy to switch from one gun to another Tools required 1 4 Allen wrench FIGURE A 5 e Rt zi V DESCRIPTION Thumb Screw Gun Receiver Bushing Connector Bar Socket Head Cap Screw INSTALLATION To change the gun bushing 1 Turn off power at the welding power source 2 Remove the welding wire from the wire drive 3 Remove the thumb screw from the wire drive 4 Remove the welding gun from the wire drive 5 Loosen the socket head cap screw that holds the con nector bar against the gun bushing Important Do not attempt to compl
113. urge Switch ss 5 2 Step 4 Step Trigger Switch Operations Process Set Up and Operation Steel and Stainless Synergic GMAW P Pulsed MIG Welding B 20 B 20 vii TABLE OF CONTENTS Page je Section B Aluminum Synergic GMAW P Pulsed MIG and GMAW PP Pulse on Pulse Welding B 21 Machine Functionality by Weld Process B 22 B 27 Gies d C r ET B 22 GMAW FCAW ire B 23 GMAW SYNERGIC ii 24 Pulse and Pulse on Pulse SYNERGIC iii B 25 STT and STT I SYNERGI emmener einen B 26 GTAW TIG 27 User MemolLles 28 Dip Switch Seltlings cre cce teras rs mer a 28 6 Optional Dual Procedure Memory Panel Operation B 28 Litt Sienaan retard tua tara ps reed nn dt den seduce eame eta B 29 porri nq Section C General Options Accessories C 1 C 3 Maintenance eis sidus aka vi essence WEE ERAGES Section D D 1 PTO 0 1 Calibration
114. ussures montantes LINCOLN 8 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 for selecting a QUALITY product by Lincoln Electric We want you to take pride in operating this Lincoln Electric Company product 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 custom
115. ve Feeder Solenoid The internal feeder MIG solenoid will turn on and off automatically while TIG welding Power source Solenoid Any gas solenoid connected to the power source will turn on and off automatically while TIG welding Notes Preflow is not available while TIG welding Postflow is available the same postflow time will be used in MIG and TIG When machine output on off is controlled via the upper right knob gas flow will not start until the tungsten touches the work Gas flow will continue when the arc is broken until the Postflow time expires When machine output on off is controlled via an arc start switch or foot Amptrol gas will begin flowing when the output is turned on and will continue flowing until the output is turned off and the Postflow time expires Crater Delay Range Off to 10 0 seconds default Off Used to skip the Crater sequence when making short tack welds If the trigger is released before the timer expires Crater will be bypassed and the weld will end If the trigger is released after the timer expires the Crater sequence will function normally if enabled Reset Consumable Weight Only appears in the list with systems using Production Monitoring Use this option to reset the initial weight of the consumable package Press the right Mode Select Button to reset the con sumable weight POWER FEED 10M SINGLE WIRE FEEDER LINCOLN a OPERATION B 14 USER DEFINED PARAMET
116. wer to see if the error clears itself If not refer to the What to Do column for the given Err PROBLEMS POSSIBLE SYMPTOMS CAUSE RECOMMENDED COURSE OF ACTION CAN communication bus off User Interface time out error Unprogrammed Weld Mode Empty Weld Table Weld Table checksum error Primary overcurrent error Capacitor A under voltage Left side facing machine Capacitor B under voltage Right side facing machine Probably due to excessive number of communication errors User Interface is no longer respond ing to the Power Source The most likely cause is fault bad connection in the communication leads or con trol cable Contact the Service Department for instructions on reloading the Welding Software Contact the Service Department for instructions on reloading the Welding Software Contact the Service Department for instructions on reloading the Welding Software Excessive Primary current present May be related to a switch board or output rectifier failure Low voltage on the main capacitors May be caused by improper input configuration When accompanied by an overvolt age error on the same side it indi cates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Linco
117. you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when 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 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 TABLE OF CONTENTS Page INSTA AU OM RP con it einn er nora a Risa Cork ada e incl CE ERE YR o ERES I ordin Section A Technical Specifications rc A 1 Sal Oly

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