Lincoln Electric 10S User's Manual
Contents
1. i o Oo 1 q e Oo CENTERLINE OF MOUNTING BRACKET 3 TOP VIEW ie MOTOR AND LEAD I CONNECTIONS p gt L3 TH 5 T SIDE VIEW pete CENTERLINE OF WIRE FRONT VIEW POWER FEED 10S LINCOLN 3 SPECIFICATIONS 3 TECHNICAL SPECIFICATIONS POWER FEED 10S Spec Type 142 1 Speed Ratio 95 1 Speed Ratio 57 1 Speed Ratio Wire Size Wire Size Wire Size Solid Cored Speed Solid Cored Speed Solid Cored K2312 1 10 200 7 32 5 32 10 300 1 8 5 32 10 450 10S Wire Feeders Input Voltage and Current Voltage Input Amperes 32V DC 7 Amps max PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 12 0 in 305 mm 14 0in 355mm 10 0in 254mm 35 0lbs 15 9kg 12 0 in 305 mm 14 0in 355mm 10 0in 254mm 80 0lbs 36 3kg 8 0 in 203 mm 6 0in 152mm 5 0in 127mm 10 0lbs 4 5kg TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 4 F to 104 F 20 C to 40 C 40 F to 185 F 40 C to 85 C WELDING PROCESSES Process Electrode Diameter Range Output Range Amperes Wire Feed Speed Range SAW 1 16 7 32 1 6 5 6 mm 200 1000 10 450 ipm 25 11 43 m minute POWER FEED 10S LINCOLN a INSTALLATION SAFETY PRECAUTIONS Read this entire ins2. S 0 383 4 4 Wvubvid SOL 43 14 H3MOd 40 POWER FEED 105 LINCOLN E F 2 DIMENSION PRINT ps L12119 CENTERLINE MOUNTING BRACKET WARNING Pl 562 2 HOLES CENTERLINE OF WIRE 6025804 df 60 A b N CENTERLINE OF WIRE 3 8 16 TAPPED HOLES 4 PLACES 7 CENTERLINE OF WIRE ISO VIEW REF ONLY POWER FEED 10S LINCOLN P NOTES POWER FEED 10S LINCOLN WARNING 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 o los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mo
3. CUCRITEOSSXSUEIL HS TFE Uo 85 ET REL BE SUCR Rr de OE AS EL FEE AMENER 0 AXIS FAIS HHR ele BEHE ET gl illai Qui al gll Gail guet LINCOLN 5 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
4. Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important 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 instructi
5. 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 rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc 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 idu PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER mue TRA
6. A 3 1 Remove all power from the POWER FEED 10S Wire Drive Disconnect the Control Cable from the POWER FEED 10S Wire Drive Connection Box Loosen the fastener from the Band Strap to the Connection Box which secures the assembly to the Motor housing and expose the leads inside of the Connection Box Locate the Motor leads These leads will go from the Motor to the Control Cable connector on the inside of the Connection Box INSTALLATION 5 A 3 Carefully disconnect the Motor leads from the har ness by pulling the quick connect terminals apart Reverse the motor leads and reconnect the quick connect terminals see Wiring Diagram Carefully replace the wire harness back into the Connection Box and place back onto the Motor housing locating over the Motor lead grommet Ensure that the tachometer leads are completely covered by the Channel that snaps into the Connection Box The Connection Box assembly should be pushed all the way up to the Motor to Gearbox Adapter Plate Before securing the Connection Box to the Motor housing with the Band Strap ensure that none of the harness leads are being pinched underneath the edges of the Connection Box and Channel Place the Band Strap into the T slot on the side of the Connection Box and wrap it around the Motor housing 10 Replace the fastener between the Band Strap and the Connection Box Tighten so that the Connection Box
7. all of the work leads into one lead Always weld in a direction away from the work leads Connect all of the work sense leads from each power source to the work piece end of the weld such that they are out of the path of the weld current For the best results when pulse welding set the wire size and wire feed speed the same for all the arcs When these parameters are identical the pulsing fre quency will be the same helping to stabilize the arcs A 5 If the voltage sensing is enabled but the sense leads are missing improperly connected or if the electrode polarity switch is improperly configured extremely high welding outputs may occur In extremely sensitive applications requiring voltage sense leads it may be necessary to route cables that contain the sense leads away from the electrode and work welding cables For more information regarding the placement of voltage sense leads see the section entitled Welding with Multiple Independent Power Waves FIGURE A 4 WORK LEADS AT THE BEGINNING OF THE WELD POWER SOURCE DIRECTION OF LEADS AT THE END OF THE WELD POWER SOURCE POWER FEED 10S LINCOLN A 6 INSTALLATION A 6 GEAR RATIO CONVERSION KITS SEE INSTRUCTIONS INCLUDED WITH CON VERSION KIT 1 Remove the 2 hex head screws and the 2 slot head screws holding the Motor to the Wire Drive Gearbox assembly 2 Remove existing Adapter P
8. ease of fixturing and locating RECOMMENDED PROCESSES The Power Feed 10S series of wire drives are best suited for submerged arc welding PROCESS LIMITATIONS MIG welding Robotic applications EQUIPMENT LIMITATIONS The Power Feed 10S series of wire drives cannot be used with the NA3 NA 4 or NA 5 series of Lincoln Automatics COMMON EQUIPMENT PACKAGES Basic Package K2344 1 Power Wave 1000 AC DC K2362 1 PF 10A Controller K2312 1 PF 10SF Wire Drive Basic Package with optional kits K2311 1 PF 10SM Motor Retrofit Kit K2370 1 PF 10S Wire Drive includes Cross Seam Adjuster and Automatic Flux Hopper with hardware to connect to TC 3 Travel Carriage K2282 1 System Interface Phase Generator POWER FEED 10S LINCOLN 2 GENERAL INFORMATION DESIGN FEATURES Closed loop speed control Knurled drive rolls Heavy cast aluminum gearbox housing and feed plate assembly Wire straightener 32Vdc permanent magnet high torque motor Conversion kit included to change speed range Voltage sense leads included for precision welding performance LOCATION OF COMPONENTS WIRE DRIVE AND COMPONENTS
9. holes See mounting hole locations Figure A 2 1 Work cable connection 3 14 pin wire feeder control cable 4 5 pin Arclink control cable to user interface 7 Electrode cable connection FIGURE A 1 POWER WAVE AC DC 1000 K2344 1 3 C3 e e POWER FEEDIOSFC CONTROL BOX CT Ke Eu 8 K1543 xx ARCLINK CONTROL CABLE K1785xx14 14 PIN FEEDER CABLE ELECTRODE SENSELEAD POWERFEED 10S WIRE DRIVE K2312 1 SUBARCCONTACT NOZZLE 231 WORK z WORK PIECE WORK SENSE LEAD FIGURE A 2 1 3 8 16 TAPPED HOLES 0 P 62 250 4 50H 4 PLACES Q 9 Mo WARNING 470 ud 50 2 69 1 a 250 g ii 5 426 I 96 CENTERLINE OF MOUNTING BRACKET 562 2 HOLES CENTERLINE OF WIRE 770 POWER FEED 10S LINCOLN A 3 CHANGING WIRE DRIVE CONFIGURATION The POWER FEED 10S Wire Drives be reconfig ured to fit in any hard automation application The POWER FEED 10S Wire Drives can be reconfig ured in such a way that the wire feed direction is reversed If this is the case the motor leads must be reversed so the wire will feed correctly Follow these instructions to reverse the motor polarity See Figure
10. D THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsUPBHEILTASESUCFEU EUR Ea fE 24758 else e SUAS MAS sis PARAH 37 amp Turn power off befor
11. NSFORMATEUR 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 chaussures montantes LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 V V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you
12. RETURN TO MAIN MENU E IMB50 A POWER FEED 105 iili For use with machines having Code Numbers 11063 11064 11127 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL LINCOLN fo Copyright 2005 Lincoln Global Inc 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 l A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WI
13. TH 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 Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing
14. TY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill e Only Qualified personnel should perform this maintenance e Turn the input power OFF at the disconnect switch or fuse box before working on this equipment e Do not touch electrically hot parts 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 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 10S To verify the wire feed speed Press the INCH DOWN switch and adjust the wire feed speed to 100 in min 2 54m min Measure the actual wire feed speed with a calibrated wire feed speed tachometer The measured wire feed speed should be within 2 of the set value MAINTENANCE D 1 SENSE LEAD FUSE There should never be any current flowing through the sense leads There is a fuse located in the sense lead circuit that is mounted in the wire drive Connection Box which protects the sense lead circuit from weld current due to incorrect configuration If this fuse ever opens check the sense lead configuration to ensure proper connections The fuse m
15. 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 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations SAFETY PR CAUTIONS DE S RET 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
16. at the ends of the leads These leads must be extended to the Work piece and the Electrode respectively The lead marked TO WORK should be extended and connected to the work piece while the lead marked TO ELECTRODE should be extended and connect ed to the nozzle These connections should be made as close to the welding arc as possible Use at least a 12 AWG wire with a proper sized ring terminal Use a screw with a lock washer and nut to make the connec tion then insulate the connection with electrical tape Proper care should be taken to protect the sense leads from becoming disconnected or damaged The loss of a sense lead connection can adversely affect welding performance ARC VOLTAGE SENSE LEAD CONNECTION TO TO ELECTRODE WORK E There are several different sense lead configurations that can be used depending on the application The ELECTRODE sense lead 67 and the WORK sense lead 21 are built into the wire drive control cable The system has multiple sense lead configurations available Consult the power source manual on how to configure the power source DIP switches for the sense leads 2 5 POWER FEED 105 LINCOLN A 5 INSTALLATION WELDING WITH MULTIPLE ARCS S pecial care must be taken when more than one arc is welding simultaneously on a single part Arc blow and arc interference may occur or be magnified Each power source requires a work lead from the work stud to the welding fixture Do not combine
17. cannot move on the Motor housing FIGURE A 3 LOOSEN SOCKET HEAD SCREW TO ROTATE FEEDPLATE REMOVE CONNECTION BOX TO CHANGE MOTOR POLARITY LOOSEN HEX HEAD SCREW ON GEARBOX STRAP TO ROTATE THE MOTOR AND GEARBOX ASSEMBLY POWER FEED 10S LINCOLN A 4 ELECTRODE AND WORK CONNECTIONS Due to the Power Wave AC DC s ability to produce either a DC positive DC negative or AC output the elec trode and work connections do not need to be reversed for the different polarities Additionally no DIP switch changes are required to switch between the different polarities All of this is controlled internally by the Power Wave AC DC The following directions apply to all polar ities Connect a work lead of sufficient size Per Table A 1 and length between the work stud located beneath the spring loaded output cover on the front of the machine and the work For convenience the work lead can be routed behind the left strain relief under the spring loaded output cover along the channels and out the back of the machine Be sure the connection to the work makes tight metal to metal electrical contact The work piece connection must be firm and secure Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding per formance To avoid interference problems with other equipment and to achieve the best possible operation route all cables directly to the work and wire feeder Avoid excessi
18. e Lead Specifications ss A 4 Welding With Multiple Arcs sise A 5 Gear Ratio Conversion Kits A 6 ACCESSO m Section C Motor Conversion Kit For 142 1 NA Style Wire Drives C 1 Maintenance ge Section D Safety 5 ced Era ED s aero EXPE EXE dva eu D 1 Routine and Periodic Engine Maintenance D 1 Calibration Specification 2 iiie diat cesa Nha letter D 1 Troubleshooting nnne nnn nnn innen nnn Section E Safety Precautions uias Drei espere Ug etapa apt Pee xc e E 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guide sisi E 2 Wiring Diagrams and Dimension Print ns Section F Parts 151 2 E 515 vi PRODUCT DESCRIPTION PRODUCT SUMMARY The Power Feed 10S series of Automatic Wire Drives are designed for hard automation submerged arc welding The heavy duty gearbox and feed plate have many years of proven reliability while a new perma nent magnet motor has been added The Power Feed 10S wire drives consist of a high torque motor and gearbox assembly with a heavy duty feed plate housing knurled drive rolls for positive accurate wire feeding of heavy welding wire The Power Feed 10S has many axes of rotation for
19. e servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e XL7TTL2A 9 AVCWRUD PRE RET BRAY FE e HE BIS AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE CRMREBIFELEWTEEU CHRRIARRARS SHAE Ro e 20 Sel Sepe Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O it ie BIR Chinese Qai dul jua Sarin e os uui ARI ge cal sd ue Aie Ao pha J jui gail e Ads cuts Fi gall l Jai y e ue Ll gt LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA
20. lace as necessary Loose electrode connections The following connections must be tight electrode cable to wire drive and power source work cable to power source and work contact tip to nozzle Rusty electrode Replace elec trode 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 10S LINCOLN 8 DIAGRAMS F 1 F 1 Jequunu epoo 1ueuudinbe y e 104 jueunredeg eui e qiGej s eui j sjeued y JO euo UO eui episui pejsed si epoo sejnomed siy Aq 40 jou Ajuo JO S SIUL LON 89E0CIN 3LIHM M 3na n Qq38 X9vi8 8 ONIGO9 16919 Yad STOEWAS 19141971 HO L93NNOO 40 3416 SV 39N3n038 ONIMAEWNN ALIAVO quvO8 Od 30 ACIS LN3NOdI OO WO SV 39N3n03 S9NIS38ADN ALIAVO d1ov1d3Ods LNdLNO 2 YY 08 Od SOVIYSLNI HOVL 258 gt YN oooo Logr 9999 19 O 9 sc XOS8MNV39 HOLOIN N 0000 008 o ooo c 4 gt I
21. late and Motor Assembly 3 Take the two long screws removed in step 1 and screw one into each of the tapped holes located on the face of fiber input helical gear Insert the screws through the full thickness of the gear and using a screwdriver wedged between the screws to prevent rotation remove the hex nut that holds the gear to the shaft Remove plain washer 4 Pull the gear from the shaft using the screws as a pulling device Be certain woodruff key is properly located on the shaft Screw the adapter plate and motor assembly mounting screws into the new fiber input helical gear from the stenciled side and place the gear on the shaft Replace plain washer tighten the hex nut and remove the adapter plate and motor assembly mounting screws from the gear 6 Support the pinion properly and with the proper size punch drive the roll pin that holds the pinion out of the shaft Pull the pinion off Remove the Ring Magnet from the pinion gear and snap it onto the new pinion gear Before installing the new pin ion gear with the Ring Magnet onto the motor shaft ensure that the flat washer is located at the bottom of the shaft Install the new pinion and replace the roll pin Cover teeth of the motor pinion and the input gear with a non fluid molydisulfide type grease such as Non Fluid Oil Corporation s A 29 Special MS Lubricant This grease can be scooped from the cavity of the gear case 8 Reassemble the
22. motor on the gearbox make sure the gears mesh properly and the adapter plate locating bead is in its cavity Replace and tighten the four screws removed in step 1 9 See the power source manual on how to config ure the power source DIP switches for the new gear ratio POWER FEED 10S LINCOLN 8 C1 ACCESSORIES c1 K2311 1 MOTOR CONVERSION KIT FOR 142 1 NA STYLE WIRE DRIVES This conver tion kit converts old NA style wire drives 1 Remove the 2 hex head screws and the 2 slot head screws holding the Motor to the Wire Drive Gearbox assembly 2 Remove existing Adapter Plate and Motor Assembly 9 The Conversion Kit Motor is shipped configured for a 142 1 gear ratio The existing gearbox must be con figured for a 142 1 gear ratio for the Conversion Kit to assemble correctly If both assemblies are not con figured for the same gear ratio this must be done before continuing See Gear Ratio Conversion Kit instructions 4 Cover the teeth of the new Motor pinion gear with a non fluid molydisulfide type grease such as Non F luid Oil Corporation s A 29 Special MS Lubricant This grease can be scooped from the cavity of the gear case First Chamber Reassemble the new Adapter Plate and Motor Assembly on the Wire Drive Gearbox making sure the gears mesh properly and the Adapter Plate locat ing bead is in its cavity Replace and tighten the 4 screws removed in step 1 POWER FEED 10S LINCOLN 8 D 1 SAFE
23. n your right side the work cable should also be on your right side X Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN SAFETY 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire weldi
24. ng 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 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot s
25. ons we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page Product 1 Recommended Processos 2 2 11 1 1 0 p ee erui a an 1 5 1 Equipment Limitations ionainn s 1 Common Equipment iii 1 Gemeral IMPOMMALION 2 Feature S ERE 2 l ocation of COMPOMEMS c as Cri aep eco a cens exa 2 SP CIICAIONS mer 3 netaat O wn 0S Section A Safety Precautions sise A 1 Non Safety Standard Equipment sn A 1 Input and Ground Connections i otro iret ra cuin veste re eurn Dua ob A 1 Location andMountilig sei i e tenen dae etin ti ed Dr rt rede nid nata ebrei arre ee A 1 Power Wave AC DC1000 Amp Subarc Systems Connections and Mounting Dimensions A 2 Changing Wire Drive Configuration A 3 Electrode and Work Connections 2 2 re asse a TOR LG A 4 Remote Sens
26. patter or metal 23 FUMES AND GASES can be dangerous 5 a 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 below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms a
27. re available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 SAFETY 7 WELDING SPARKS gt 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 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 container
28. rm the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10S LINCOLN 8 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Drive rolls turn but wire will not Wire jammed or kinked on route feed or wire feeding is rough or through wire drive Remove wire uneven from wire drive then feed in new wire Note any obstruction Incorrect drives rolls and or guide tubes or incorrect pres sure setting Ensure drive rolls and or guide tubes are stamped with wire diameter being used Replace if necessary Check for proper pressure setting Worn drive rolls Replace or reverse if split type Partially flashed or melted con If all recommended possible areas tact tip Replace contact tip of misadjustments have been checked and the problem persists contact your local Lincoln Variable or hunting arc Contact tip worn or incorrect Authorized Field Service Facility size Replace contact tip Worn or undersized work cables or poor connections to work Inspect and repair or rep
29. s 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 6 h Also see item 1 c LINCOLN CYLINDER may explode 22238 sr 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 Cylinders 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
30. tallation section before you start installation WARNING ELECTRIC SHOCK can kill Only qualified personnel should per e form this installation Turn the input power OFF at the dis connect switch or fuse box before working on this equipment Turn off the input power to any other equip ment connected to the welding sys tem at the disconnect switch or fuse box before working on the equip ment Do not touch electrically hot parts NON STANDARD SAFETY INFORMATION CAUTION PARTS MAY BE gt AT WELDING VOLTAGE ATTENTION LES PIECES ELECTRIC PEUVENT TRE A LA TENSION DE SOUDAGE can kill 525815 VM CAUTION The PF 10S series of wire drives be at weld ing voltage potential when the output of the power source is active INPUT AND GROUND CONNECTIONS Only a qualified electrician should connect the POWER FEED 105 Installation should be made in accordance with the appropriate National Electrical Code all local codes and the information in this manu al LOCATION AND MOUNTING The POWER FEED 105 will operate in harsh envi ronments HIGH FREQUENCY PROTECTION Locate the POWER FEED 10S away from radio con trolled machinery POWER FEED 10S LINCOLN A 1 2 INSTALLATION A 2 POWER WAVE AC DC 1000AMP SUBARC MOUNTING DIMENSIONS SYSTEM CONNECTIONS The PF 10S can be mounted by using the four 3 8 16 See Figure A 1 tapped holes or the two 0 562 through
31. through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety nes 5 minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is o
32. toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux 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 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de
33. uill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR LiH 7 amp nf dchsn zucct MLMPT APSSAPREBS E GUB S Oa E EERTE Xe uc Bp HZA Weal AMI d ous uil el jad oa Y O ay Ast gl uit celal AL usu DA dax ule Y Jio moe 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 inflamaveis bem guarda dos ORAPTUSOOM EA e i8 IEEE IIS eis Jo ALD al gll pis e Ac AI uie 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 e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HAUSHERMRELTTF EU RRR HEBS SOSRSHR ez 119 59 s ESSAI dady dise ule Lily vues al ad ne 4 aun y READ AND UNDERSTAN
34. ust be replaced with a comparable fuse with a rating of less than 1 amp before welding The fuse being open or missing would have the same effect on the welding as having a disconnected sense lead POWER FEED 10S LINCOLN 8 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A 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 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perfo
35. ve lengths and do not coil excess cable Connect the electrode cable to the ELECTRODE stud on the power source located behind the cover plate on the lower left side For convenience the cable can be routed through the oval hole in the left cable tray before being connected to the output terminals Connect the other end of the electrode cable to the nozzle Be sure the connection makes tight metal to metal electrical contact The electrode cable should be sized according to the specifications given in Table A 1 TABLE A 1 Output Cable Guidelines Total Cable Length ft m Duty Cycle Electrode and Work Combined Cable Size Copper Number of Parallel Cables 3 0 95 mm 0 0 to 250 76 2 410 120 mm 0 0 to 250 76 2 10096 When using inverter type power sources like the Power Wave use the largest welding electrode and work cables that are practical 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 CAUTION Excessive voltage drops at the work piece con nection often result in unsatisfactory pulse weld ing performance INSTALLATION A 4 REMOTE SENSE LEAD SPECIFICATIONS The Power Feed 10S has sense lead connections at the Connection Box mounted to the motor These sense leads are critical to the accuracy of the Power Wave welding process Ring terminals are provided
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