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Lincoln Electric IM584-D User's Manual

1. 1 o SETTING DIP SWITCHES IN THE A CONTROL BOX DN s2 1 2 3 4 5 6 7 8 There are two DIP switch banks on the mother board H of the Control Box They are labeled S1 and S2 and are located and oriented as shown in Figure A 3 FIGURE A 3 Off On 1 Network Group ID MSB Assigns Control Box to a specific group Off is factory setting 2 Network Group ID LSB Assigns Control Box to a specific group Off is factory setting S1 DIP Switch Bank on Control Box Motherboard For software version S24004 3 amp up Standard speed gearbox limits adjustable High speed gearbox limits adjustable WFS Display inches minute WFS Display meters minute Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing Left Display is actual weld current when weld current is flowing CC modes override this switch regardless of position Left Display is always preset weld cur rent when weld current is not flowing and actual weld current when weld current is flowing Run in Minimum Speed Available Run in weld WFS 5 6 If any option containing a Run in setting is connected to the motherboard it automatically overrides this switch regardless of position Memory change with trigger disabled Memory change with trigger enabled Acceleration MSB Sets acceleration rate for wire drive see below Acceler
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3. BK 87 48 HAMAL HHPI Ash FAAAZI4 37 amp oe daly ay e jul aach 0624 e uu Abt Ge call us e Turn power off before 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 N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas X7TTLZA KR UAURBUD POR EF BRAT FE FTF e HENKE SHA AHS Au Aj alil 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 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 e ID RALE CREATE Se 2 e do Gel tee OMAR jlgall l a Ja y e S i di Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Hx BIR Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE P
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5. Network Group ID LSB Assigns Control Box to a specific group Off is factory setting eee parna rasan Note the factory shipped settings for the S2 switches are as follows 10 and Dual Domestic switches 1 7 OFF 8 ON 10 and Dual European switches 1 2 4 7 OFF 3 8 PF 11 Domestic switches 1 3 5 7 OFF 4 8 ON PF 11 European switches 1 2 5 7 OFF 3 4 8 ON MSB Most Significant Bit or Byte This is the bit in a binary number or DIP switch bank that is furthest to the left LSB Least Significant Bit or Byte This is the bit in a binary number or DIP switch bank that is furthest to the right POWER FEED 10 LINCOLN 8 A 10 INSTALLATION A 10 Setting Wire Drive Acceleration Rate Using All software versions DIP Switch S1 on the Control Box Motherboard orm oem Off Off On Off Acceleration 2 Off ow Dmm ECS Acceleration 5 fast factory setting SETTING DIP SWITCHES IN THE WIRE ON DRIVE 123456 7 8 9 4 There is one DIP switch bank on the control board of the wire drive labeled S1 and is located and ori ented as shown in Figure 4 FIGURE A 4 On D eege gt asson tearena rarer weon emm
6. GMAW Pulse Procedures In these procedures the actual voltage greatly depends on the waveform used The peak currents background currents rise times fall times and pulse times all affect the actual voltage The actual voltage for a given wire feed speed is not directly predictable unless the waveform is known In this case it is not practical to preset an actual voltage for the procedure Instead an arc length adjustment is provided The machine knows what the best arc length is at the given wire feed speed but allows the operator to change it The arc length trim usually referred to simply as trim can be adjusted between 0 500 and 1 500 on the Control Box s Volts Trim display An Trim of 1 000 means that no adjustments will be made to the preset arc lengths A Trim setting less than 1 000 decreases the preset arc lengths The arc length trim adjustment is factored in at all wire feed speed settings Increasing the Trim by 10 percent at a given wire feed speed also increases all the other arc length trim set tings of the procedure by 10 percent POWER FEED 10 LINCOLN C 6 ACCESSORIES C 6 Lincoln Power Wave power sources utilizes a control scheme known as adaptive control in all pulse modes Because the Power Wave utilizes adaptive control it can adjust the pulsing parameters based on changes in the arc due to changes in the electrical stickout of the electrode Contact Tip to Work Distance CTWD is the distance fro
7. Magnum 200 300 400 with K466 1 connector kit and Magnum 550 guns with the K613 1 gun connection kit K1500 2 TWECO 42 44 TYPE CONNEC TION The K1500 2 gun adapter comes factory installed on the Power Feed 10 wire feeder Use this adapter for guns that have a Tweco 2 4 connector Such guns include Magnum 200 300 400 guns with K466 2 con nector kit and completely factory assembled Magnum guns that are factory equipped with the K466 2 con nector such as the K471 21 22 and 23 dedicated Magnum 400 guns and the K497 20 and 21 Magnum 200 guns K1500 3 TWECO 5 CONNECTION For Magnum 550 gun with K613 2 Connection Kit and any other gun having a Tweco 5 connector K1500 4 MILLER CONNECTION For any gun having a newer style Miller connector Install gun adapters per the instructions shipped with it POWER FEED 10 LINCOLN C 11 CONDUIT ADAPTERS K1546 2 ADAPTER for use with Lincoln Magnum conduit and E Beam conduit wire sizes 1 16 120 For Magnum conduit Install the K1546 2 gun adapter at the incoming end of the feed plate secure with the set screw located at the back of the feed plate If a brass fitting is supplied with the conduit remove it from the feeder end of the conduit by unscrewing it Insert the conduit into the K1546 2 secure the conduit by fastening it the the adapter with the supplied knob screw For E Beam Conduit Install the K1546 2 gun adapter at the incoming end of the
8. Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION 14 Displays and or indicator lights The encoders switches may be all recommended possible areas of do not change when their corre faulty misadjustment have been checked sponding switches and or knobs and the problem persists Contact are activated to request a b Check for broken harness wire s your local Lincoln Authorized change or harness disconnected from Field Service Facility intended location A 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 10 LINCOLN E 8 TROUBLESHOOTING E 8 Observe all Safety Guidelines detailed throughout this manual 15 Display s are blank a Power source is OFF b Feeder supply or fuse circuit at power source is blown or tripped or defective harness or cabling c Display or Circuit Boards may be faulty 16 Dual Procedure is not function a Gun has not been selected at the ing when using remote dual pro control box Set dual procedure cedure switch Status lights are switch on Circuit Board to gun solid green on Circuit Boards Refer to operating instructions and head boards Faulty remote dual procedure If all recommended pos
9. RETURN TO MAIN MENU IM584 D August 2007 Power Feed 10 Wire Drive amp Control Box Boom Mount or Bench Model For use with Power Feed 10 Control Box Boom Mount Code 10436 10615 Power Feed 10 Wire Drive Boom Mount Code 10437 10616 10782 Power Feed 10 Boom Package Code 10435 10612 Generic 10493 10613 12 Zipline 10494 10614 16 Zipline 10779 Generic 10767 10780 12 Zipline 10768 10781 16 Zipline Power Feed 10 Bench Model Code 10438 10617 10760 10783 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 A _ Designed Manufactured Under by ENT de 2 2007 Lincoln Giobal e 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 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhau
10. ez 712 Sol Soares y due Lily us cl di READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes 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 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 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 exhaust o para remover fumo da zona respirat ria eta A 59tEM d e
11. Power Feed sys tem are connected in a daisy chained fashion This means that the first component in the system always the Power Wave 455 must have an output recepta cle The last component in the system typically the Wire Drive must have an input receptacle Every component in between must have both an input and output receptacle Output receptacles are character ized by having insulated socket connections while input receptacles have uninsulated pin connections In a factory supplied bench system the Power Wave 455 has an output receptacle and the Wire Drive has an input receptacle The connection between the Control Box and the Wire Drive is internal no external cables or receptacles are required In a factory supplied boom system the Power Wave 455 has an output receptacle the Control Box has both input and output receptacles and the Wire Drive has an input receptacle If a bench feeder is to be converted to a typical boom feeder both input and output receptacles must be installed in the Control Box An Input Output Receptacle Kit K1548 1 is available for this purpose Instructions for installing the receptacles in a Control Box are included with the kit Alternately a bench feeder can be converted to a non typical boom system by installing an output receptacle in a Wire Drive use K1549 1 and an input receptacle in a Control Box use K1550 1 This sys tem would meet the rule stated above This means th
12. but neither the power source nor the drive motor will be energized POWER FEED 10 LINCOLN B 7 OPERATION B 7 WIRE DRIVE PC BOARD ADJUSTMENTS ELECTRODE POLARITY The system needs to be aware of the electrode polari ty A DIP switch setting on the Wire Drive PC board is used for this purpose See INSTALLATION Section Setting DIP Switches in the Wire Drive GEAR BOX RATIO The systems needs to know which gear has been installed on the Wire Drive low or high speed A DIP switch setting on the Wire Drive PC board is used for this purpose See INSTALLATION section Wire Drive Ratio for information on how to set the DIP Switch WIRE REEL LOADING READI REELS SPOOLS OR COILS To Mount a 30 Lb 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter The Spindle should be located in the LOWER mounting hole 1 Depress the Release Bar on the Retaining Collar and remove it from the spindle See Figure B 1 2 Place the Adapter on the spindle 3 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle 4 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 5 Position the Readi Reel so that it will rotate in a direction when feeding so as to be de reeled from bottom of the coil 6 Set one of the Readi Reel inside cage wires on the slot in the retaini
13. 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 soudage Utiliser des lunettes avec crans lateraux dans les zones o 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 con
14. persists then replace the Circuit Board mother PC 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 10 LINCOLN E 12 TROUBLESHOOTING E 12 Observe all Safety Guidelines detailed throughout this manual 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 RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION Err Microprocessor RAM error in Control Turn Power off at power source Wait 5 seconds Turn power back on If Err 211 is displayed again then replace CB mother PC board Microprocessor RAM Error in object Cycle power as in Err 211 If Err 212 board other than Control Box Such lis still displayed then replace the PC as feed head board in the object with the fault The object with the fault should be solid red on its status LED three dashes Appears on right display of Circuit This is an indication that a constant Board module that contains the sta current such as stick or gauge mode tus LED has been selected Turning the right encoder clockwise when in this state will activate output to Power Source Turning the right encoder counter clockwise wil
15. 1 on these models Install the 5 8 18 male outlet of the regulator to the 5 8 18 female gas inlet on the back panel of the wire drive Secure fitting with flow adjuster key at top Attach gas supply to 5 8 18 female inlet of regulator per instructions above WIRE SPINDLE PLACEMENT The reel stand provides two mounting locations for the 2 inch diameter wire reel spindle to accommodate var ious reel sizes Each mounting location consists of a tube in the center of the reel stand and locating slots on the outside of the reel stand The bolt used with a plain washer and lock washer slides through the tube from the side of the reel stand The bolt should be threaded into the wire spindle such that the tabs on the brake mechanism align with the locating slots then tighten INSTALLATION A 13 The upper location must be used for 50 60 Ib Readi Reels Spools and Coils For smaller coils 44lb 3016 1010 etc the spindle can be placed in either the upper or lower location The goal is to make the wire path from the coil to the wire drive an entry into the incoming guide tube that is as straight as possible This will optimize wire feeding performance WATER CONNECTIONS WATER COOLED GUNS FOR If a water cooled gun is to be installed for use with the Power Drive 10 a K590 5 Water connection kit can be installed Contained in the kit are the water lines and quick connect water line fittings that install in the wire feed he
16. Assemblies with Standard A 11 Gun and Cable Assemblies with Fast Mate Connection A 11 General Gun Connection Guidelines A 12 GMAW Shielding Gas sise A 13 Gas G ard Regulator essiensa enei eet ette Eee eed e De LEM d aka ern A 13 Wire Spinde Placement Po A 13 Water Connections For Water Cooled Guns A 13 Wire Feed Shut Down Circuit Optional ss A 13 Optional Features Installation A 14 Optional Panels for Control BOX Rc eve dee A 14 General Panel Installation Guidelines A 14 Boom and Bench Converslons eiA iaaa A 14 Section Safety Precautions 3 cti eerie te ei eae as B 1 Prod ct Descriptions E B 1 Recommended Processes and B 1 npa MuR s B 1 BOX mL B 1 Operation with Previous Software Versions B 6 Wire Drive Operation B 6 2 Step 4 Step Switch Operation enne nnns B 6 Cold Feed Gas Purge Switch B 6 Wire Drive PC Board Adjustments B 7 Wire R el Loading tier ere tr a ree pp Ma epe item B 7 Feeding Electrode and Brake 422 122 B 9
17. boom frame work Includes an easily adjustable friction brake for control of overrun a 2 spindle is standard on Power Feed 10 Bench model When a 2 51 mm spindle is used with Readi Reels or coils not on 12 305 mm O D spools an adapter is required K1504 1 COIL ADAPTER Permits 50 lb to 60 Ib 22 7 27 2 Kg coils to be mounted on 2 51 mm O D spindles K435 COIL ADAPTER Permits 14 Ib 6 kg Innershield coils to be mounted on 2 51 mm O D spindles K363P READI REEL ADAPTER Adapts Lincoln Readi Reel coils of electrode 30 Ib 14 kg and 22 Ib 10 kg to a 2 51 mm spindle Durable molded plastic one piece construction Designed for easy loading adapter remains on spin dle for quick changeover K438 READI REEL ADAPTER Adapts Lincoln Readi Reel coils of electrode 50 60 Ib 22 7 27 2 kg to a 2 51 mm spindle POWER FEED 10 LINCOLN C 10 GUNS AND GUN ADAPTERS The Power Feed 10 wire feeder is equipped with a factory installed K1500 2 gun connection Kit This kit is for guns having a Tweco 2 4 connector The Power Feed 10 has been designed to make connect ing a variety of guns easy and inexpensive with the K1500 series of gun connection kits Gun trigger and dual procedure lead connections connect to the single 5 pin receptacle on the front of the wire drive box MAGNUM 200 300 400 GUNS The easiest and least expensive way to use Magnum 200 300 400 guns with the Power Feed 10
18. changing the external drive gear The Power Feed 10 is shipped with both a high speed and a low speed gear As shipped from the factory the low speed high torque gear is installed on the feeder If this is the desired gear ratio no changes need to be made SELECTING THE PROPER GEAR RATIO See the Technical Specifications at the front of this section for feed speed and wire size capabilities with high and low speed gear ratios To determine whether you should be using the high or low speed ratio use the following guidelines If you need to operate at wire feed speeds above 800 IPM 20 m m you will need to install the high speed gear large 30 tooth 1 6 inch 41mm diameter gear If you do not need to run at wire feed speeds in excess of 800 IPM 20 m m you should use the low speed gear small 20 tooth 1 1 inch 28mm diame ter gear Using the low speed ratio will provide the maximum available wire driving force Note If you are feeding only small diameter wires you may at your option install the high speed ratio CHANGING THE WIRE DRIVE RATIO Changing the ratio requires a gear change and a PC board switch change The Power Feed 10 is shipped with both a high speed and a low speed gear As shipped from the factory the low speed high torque gear is installed on the feeder For identification pur poses the low speed high torque gear has 20 teeth and is 1 1 inches 28mm in diameter The high speed gear has 3
19. feed plate secure with the set screw located at the back of the feed plate Insert the conduit into the K1546 2 secure the conduit by fastening it the the adapter with the supplied knob screw DUAL PROCEDURE SWITCH OPTIONS K683 3 DUAL PROCEDURE SWITCH Kit includes gun switch and mountings for Lincoln Innershield and Magnum guns with 15 ft 4 5m con trol cable and 5 pin plug with two leads to connect to gun trigger Connect the 5 pin plug of the K683 3 Dual procedure Switch to the Power Feed 10 Wire Feeder Trigger Dual Procedure 5 socket receptacle The two lead plug cord extending out of the 5 pin plug of the Dual Procedure switch is to be connected to the two trigger leads of the welding gun per instructions shipped with the kit K683 1 DUAL PROCEDURE SWITCH The K683 3 Dual Procedure Switch is the recom mended method of obtaining dual procedure for non Fast Mate guns but a K683 1 can be used For using a K683 1 with a fast mate gun see USING DUAL PROCEDURE WITH FAST MATE GUNS A K683 1 Dual Procedure Switch can be used on the Power Feed 10 if a K686 2 adapter is used The K686 2 kit includes the gun switch and mountings for Lincoln ACCESSORIES 11 Innershield and Magnum guns with 15 ft 4 5 m con trol cable and 3 pin plug K686 2 Adapter permits the 3 pin plug from the K683 1and 5 pin gun trigger plug to be connected to the 5 pin trigger dual procedure receptacle on the wire feeder USING DUAL PROCEDUR
20. is maybe electrically open Leads red green alternating between 570 and 572 in wire feed head colors every second Unit tries to recover after 30 seconds and The wire drive motor may be may repeat again overloaded Check for mechani cal restrictions in the wire feeding If all recommended possible areas of path misadjustment have been checked and the problem persists Contact your local Lincoln Authorized 6 Drive roll does not turn although Check for loose or broken leads Field Service Facility arc voltage is present and solenoid at the wire drive motor is on Feed head and Control Box status LEDs are both solid green Defective wire feed motor or feed head PC board Note With WFS set to max control board should supply 24 VDC to motor leads 550 551 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 10 LINCOLN 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual No wire feed solenoid or arc a Faulty gun trigger switch The gun voltage Status LEDs are solid trigger switch or circuit may be green faulty Check or Replace No control of wire feed a Defective motor tach or control All status lights are solid green PC board or harness Check for Prese
21. locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 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 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks a
22. run in etc 2 Opening the trigger after the welding arc is estab lished allows the weld to continue as long as cur rent flows If the arc goes out the 4 step cycle is reset 3 Closing the trigger again allows the weld to contin ue 4 Opening the trigger again ends the arc begins burnback postflow etc When using 4 Step Logic With Crater Fill ON 1 Closing the gun trigger initiates the welding sequence preflow run in etc 2 Opening the trigger after the welding arc is estab lished allows the weld to continue as long as cur rent flows If the arc goes out the 4 step cycle is reset 3 Closing the trigger again changes the wire feed speed and the Volts Trim to the Crater values and the weld to continues 4 Opening the trigger again ends the arc begins burnback postflow etc COLD FEED GAS PURGE SWITCH The Wire Drive has a Cold Feed Gas Purge Switch located near the gun connector This is an up down center off momentary toggle switch When held in the up position the Wire Drive will feed wire but neither the power source nor the gas sole noid will be energized When cold feeding the feed speed can be adjusted by rotating the WFS encoder knob on the Control Box Adjusting the cold feed will not affect the run in or welding wire feed speed When the cold feed switch is released the cold feed value is saved When this switch is held in the down position the gas solenoid valve is energized
23. the A position Make all desired settings on the Control Box Settings are automatically saved as changes are made Do the same for procedure B If using a gun switch to select procedures set the switch to Gun Switch Procedure A is the default if no gun switch is present Settings are saved at power down K1542 9 Dual Procedure Memory Panel This panel provides two functions Dual Procedure and Memory Dual Procedure provides for setting and manual selection of two procedures Selection can be done at the panel or through a dual procedure weld ing gun switch connected to the Wire Drive trigger receptacle Memory provides six independent storage locations for Control Box settings All selections are done with push buttons and indicator lights Dual Procedure can be used without making use of Memories the opposite is also true To set Procedure A hit the Procedure button until the A LED illuminates Make all desired settings on the Control Box Settings are automatically saved as changes are made Do the same for procedure B using a gun switch to select procedures hit the Procedure button until the Gun LED illuminates When in the Gun mode is selected either light A or B will be flashing The flashing light identifies the Procedure A or B which is selected by a dual proce dure gun switch If no dual procedure switch is plugged in the Procedure defaults to A Settings are saved at power down To load a memory start by s
24. tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra MARHE FRANEACRHEUCE ATUBSHELTFEL e AER H amp e B RMI HR SHES He 8 AU PHA 2749 Su ASAI OMAR Gall oye ag iY d ily gS welll AA Gadi JS aua Vile 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 e Mantenha inflam veis bem guarda dos SODMTOBEEER o 5 fbi SRE 3 Sais AIX uie Jus ALIM Aal 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 vista ouvido corpo RER
25. to expose rolls and wire guides 3 Remove Outer Wire Guide by turning knurled thumb screws counter clock wise to unscrew them from Feedplate 4 Remove drive rolls if any are installed by pulling straight off shaft Remove inner guide 5 Insert inner Wire Guide groove side out over the two locating pins in the feedplate 6 Install each drive roll by pushing over shaft until it butts up against locating shoulder on the drive roll INSTALLATION A 11 shaft Do Not exceed maximum wire size rating of the wire drive 7 Install Outer Wire Guide by sliding over locating pins and tightening in place 8 Engage upper drive rolls if they are in the open position and close Pressure Door TO SET DRIVE ROLL PRESSURE see Drive Roll Pressure Setting in OPERATION GUN AND CABLE ASSEMBLIES WITH STANDARD CONNECTION The Power Feed 10 wire feeder is equipped with a factory installed K1500 2 gun connection Kit This kit is for guns having Tweco 72 84 connector Power Feed 10 has been designed to make connect ing a variety of guns easy and inexpensive with the K1500 series of gun connection kits Gun trigger and dual procedure lead connections connect to the single 5 pin receptacle on the front of the feed head box See Gun Adapters in ACCESSORIES section GUN AND CABLE ASSEMBLIES WITH FAST MATE CONNECTION including the Magnum 450 Water Cooled gun A K489 7 adapter will install directly into the wir
26. to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any 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 co
27. to use correct eye head body protection 9 If used be sure shielding gas valve is turned on 10 Position electrode over joint End of electrode may be lightly touching the work 11 Lower welding helmet close gun trigger and start welding Hold the gun so the contact tip to work distance gives the correct electrical stickout as required for the procedure being used 12 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes OPERATION B 10 out and Postflow time if used is over 13 If required starting can be optimized by adjusting the acceleration and or run in speed Refer to Control Box Operation in this section WIRE REEL CHANGING At the end of a coil remove the last of the old elec trode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the follow ing procedure 1 Cut the end of the electrode off at the gun end Do not break it off by hand because this puts a slight bend in the wire making it difficult to pull it back through the nozzle 2 Disconnect the gun cable from the gun connector on the Power Feed 10 wire drive unit and lay the gun and cable out straight 3 Using pliers to grip the wire pull it out of the cable from the connector end 4 After the electrode has been removed reconnect the gun cable to the drive Load a new reel of elec trode per the instructions in Wire Reel Loading
28. up or down adjusts the displayed value in the correspond ing direction Holding the switch in either direction will cause the display to move quickly in the correspond ing direction until the switch is released or the upper or lower parameter limit is reached To energize the output studs in either CC Stick mode the right Control Display panel knob labeled Volts Trim must be used The Volts Trim knob must be turned clockwise roughly a quarter revolution to energize the output studs The Volts trim display will indicate On when the studs are energized Similarly turning the knob a quarter turn counter clockwise de energizes the output studs If a CC Stick weld mode is entered through use of the Dual Procedure the studs will be in the same state as when they were last used If a CC Stick weld mode is entered through a Memory recall the studs will be de energized K1542 12 MSP2 Panel This panel provides a selection of over 25 weld modes including CV pulse FCAW and CC through a toggle switch and indicator lights LEDs It allows for adjustment of all set up parameters Preflow Run In Arc Control Burnback Postflow and Crater through an up down toggle switch indicator lights and a 3 digit display To adjust a set up parameter Weld Mode being one of those parameters first select one of the set up parameters for adjustment and then adjust the dis played value up or down Set up parameters are selected with
29. 0 teeth and is 1 6 inches 41mm in diame ter WARNING Power down the Power Feed by turning off its companion Power Wave power source For maxi mum safety disconnect the control cable from the Power Feed POWER FEED 10 LINCOLN A 6 INSTALLATION A 6 RATIO CHANGE PROCEDURE 1 2 Pull open the Pressure Door Remove the Phillips head screw retaining the pin ion gear to be changed and remove the gear If the gear is not easily accessible or difficult to remove remove the feed plate from the gearbox To remove feed plate a 23 2 9 Loosen the clamping collar screw using 3 16 Allen wrench The clamping collar screw is accessed from the bottom of the feed plate It is the screw which is perpendicular to the feeding direction Loosen the retaining screw which is also accessed from bottom of feeder using a 3 16 Allen wrench Continue to loosen the screw until the feed plate can be easily pulled off of the wire feeder Loosen but do not remove the screw on the lower right face of the feed plate with a 3 16 Allen wrench Remove the screw on the left face of the feed plate If changing from high speed larger gear to low speed smaller gear line the lower hole on the left face of the feed plate with the threads on the clamping collar Line the upper hole with the threads to install larger gear for high speed feed er If feed plate does not rotate to al
30. 0115 yO M alouoi _7 4 anon SNE Lr XOS8V39 HO 1ON 7 098 aN 118 4 wats ZLG Vers ET al 699 GIONOL ERR 098 0 8 sv9 4315 aasn al HONI 4109 14315 2 SOVAYALNI yasol LSS OM NOLLO3NNOO H3SnOl SNISN3S SOVLIOA 319VLd1934 NNO 3HIM OL 444 H3MOd INVHOVIO 2004193713 m F 2 POWER FEED 10 LINCOLN E F 3 664011 000 8706 o 1 H i 09 8 _ F 3 2 20 o gt ve NOISNAWIG 8981 POWER FEED 10 LINCOLN LELECTRIC NOTES POWER FEED 10 LINCOLN NOTES POWER FEED 10 LINCOLN NOTES POWER FEED 10 LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO BIR Chinese 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 Aislese del trabajo y de la
31. 4 2 is different than described earlier in this section The differences are as follows The Memory Dual Procedure panel is not a valid option MX K1542 1 and MSP K1542 8 are are used in place of the MX2 and MSP2 options Limits cannot be set The key difference in the MX MSP panels compared to the MX2 MSP2 panels is the Spot function In the old software a 0 1 to 2 5 second Spot function was available on these two panels No Crater function was available Crater replaced Spot in the graphics on these two panels An upgrade kit is available to change the software from S24004 2 to the latest version of Control Box software Once the upgrade is done the Dual Procedure Memory panel becomes a valid option limits can be set and Spot is replaced by Crater WIRE DRIVE OPERATION The most frequently used Wire Drive settings are external some features are accessed by internal set tings WIRE DRIVE SETTINGS EXTERNAL 2 STEP 4 STEP SWITCH The Wire Drive has a 2 Step 4 Step switch located on the gun side of the Status LED This switch has no effect in CC modes of operation such as stick welding When using 2 Step Logic 1 Closing the gun trigger initiates the welding sequence preflow run in etc 2 Opening the gun trigger ends the arc begins burn back postflow etc When using 4 Step Logic With Crater Fill OFF 1 Closing the gun trigger initiates the welding sequence preflow
32. ARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR gt RRVE NOX H ODI REE ERA E TEMUCTSU TL HDT FEU SA EE ED EE T ECKE ECKE Azo St i SAAD ziel z i OK EPA ai gl ud al L LINCOLN 8 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
33. CESSORIES section of this manual along with their installation instructions as are all other pieces of optional equipment The PF 10 Control Box is designed to accept three control panels two large and one small panels are needed to make up a complete control panel for the Control Box Panels can be mounted in one of three positions Upper middle and lower Each Control Box is shipped with a Control Display CD panel a large panel installed in the upper posi tion and a CV Gouge CV G panel another large panel in the lower position The middle position is filled with a blank panel The CD panel must be installed in every Control Box The small panel can be blank it can be a Dual Procedure panel or a Dual Procedure Memory panel The remaining large panel can be one of the following CV G M MX2 or MSP2 The features of each are described in the Operation section of this manual There are extra mounting holes in the upper and mid dle positions which allow the upper two panels to be interchanged Instead of the upper middle and lower panels being large small and large they could be installed in the order small large large This may be done for convenience sake or to take advantage of the Large Security Door option Note The CD panel must be installed in either the middle or the upper position its harness is not long enough to allow installation in the lower position INSTALLATION A 14 GENERAL PANEL IN
34. Drive Roll Pressure Setting enion ee 9 Procedure for Setting Angle of Feedplate B 9 Gas Guard Regulator Selling reris cree in rm in ne B 9 Making a OR B 10 Wire Reel CHANGING B 10 Wire Feed Overload Protection sr B 10 Component Status Lights ss B 11 Stat s Light States eee festen eme Ec eiit eere esu dan ETA B 11 Section Drive Roll and Guide Tube Kits C 1 eui gue 5 2 Maintenance Section D Safety Preca Surius asus tee D 1 2 cioe tede deett came D 1 Avoiding Wire Feeding Problems aec nonsense eee D 1 Periodic RR a ERI t aur oen etant ent D 1 Procedure for Removing Feedplate from Wire Feeder D 1 vii TABLE OF CONTENTS Page Troubles holi 2 Section Safety eT 1 Troubleshooting Guide 2 Procedure for Replacing PC E 13 22 M Section F Wiring Power Feed 10 Control Box F 1 Wiring Power Feed 10 Feed Head F 2 DIMENSI
35. E WITH FAST MATE GUNS There are a number of different options available for using dual procedure with Fast Mate guns These configurations are outlined below along with any addi tional required equipment USING DUAL SCHEDULE WITH FAST MATE GUNS ON 10 SERIES FEEDERS Configuration 1 K489 7 Dual Schedule Fast Mate adapter K575 Magnum 400 DS FM gun or competitive DS FM gun Configuration 2 K489 7 Dual Schedule Fast Mate adapter K683 1 Dual Procedure Switch 3 pin K686 2 Y adapter 5 pin to 5 pin Non DS Fast Mate gun Magnum 450WC Magnum 200 Magnum 300 Magnum 400 and others POWER FEED 10 LINCOLN C 12 K590 5 WATER CONNECTION KIT FOR DRIVE ONLY Install per the instructions shipped with the kit K1536 1 WATER FLOW SENSOR KIT Install per the instructions shipped with the kit K659 1 GAS GUARD REGULATOR Adjustable flow regulator with removable adjuster key for CO2 and Argon blend gases Mounts onto feeder inlet and reduces gas waste and arc start blow by reducing surge caused by excess pressure in supply hose Install the 5 8 18 male outlet of the regulator to the 5 8 18 female gas inlet on the back panel of the wire drive Secure fitting with flow adjuster key at top Attach gas supply to 5 8 18 female inlet of regulator per INSTALLATION section K1557 1 SWIVEL MOUNT The K1557 1 Swivel mount attaches to the power source This kit includes a feeder adapter plate that allo
36. Flux Cored CC Stick soft and CC Stick Crisp through a toggle switch and indicator lights LEDs It allows for adjustment of all set up parameters Preflow Run In Arc Control Burnback Postflow and Crater through an up down toggle switch indicator lights and a 3 digit display Weld modes are selected with the Mode Select switch an up down center off momentary toggle switch Moving the switch bat up or down moves the Weld Mode LED in the corresponding direction Holding the switch in either direction will cause the indicator to move quickly in the corresponding direc tion until the switch is released or the upper or lower limit is reached To adjust Set Up parameters first select the Set Up parameter for adjustment and then adjust the dis played value up or down Set Up parameters are selected with the Select switch an up down center off momentary toggle switch Moving the switch bat up or down moves the Weld Mode LED in the corresponding direction Holding the switch in either direction will cause the indicator to move quickly in the corresponding direc tion until the switch is released or the upper or lower limit is reached POWER FEED 10 LINCOLN B 4 OPERATION B 4 The value of the active Set Up parameter as defined by the Set Up LED is displayed on the MX2 panel Set Up display The value can be modified with the Set switch The Set switch is an up down center off momentary toggle switch Moving the switch bat
37. KP1507 035A KP1507 040A KP1507 3 64A KP1507 1 16A KP1507 3 32A c2 ACCESSORIES 2 DESCRIPTION AND INSTALLATION OPTIONAL CONTROL BOX PANELS A number of Optional Features are available for use with Power Feed 10 Some Installation information is provided in this section REFER TO THE INSTRUC TIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLA TION OPTIONAL PANELS FOR CONTROL BOX All optional panels for the control box are described in the ACCESSORIES section of this manual along with their installation instructions as are all other pieces of optional equipment The PF 10 Control Box is designed to accept three control panels two large and one small panels are needed to make up a complete control panel for the Control Box Panels can be mounted in one of three positions upper middle and lower Each Control Box is shipped with a Control Display CD panel a large panel installed in the upper posi tion and a CV Gouge CV G panel another large panel in the lower position The middle position is filled with a blank panel The CD panel must be installed in every Control Box The small panel can be blank it can be a Dual Procedure panel or a Dual Procedure Memory panel The remaining large panel can be one of the following CV G M MX2 or MSP2 The features of each are described in the Operation section of this manual There are extra mounting holes in the upper and m
38. N for cable installation instructions 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 455 Power Feed system The use of non standard cables especially in lengths greater than 25 feet 7 6 meters can lead to commu nication 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 There 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 CABLE ASSEMBLIES K1543 Control cable only Available in lengths of 8 2 4m 16 4 9m 25 7 6m 50 15 2m and 100 30 5m K1544 Control cable and a 3 0 85 mm2 electrode cable with stud terminal It is rated at 600 amps 6096 duty cycle and is available in lengths of 8 2 4m 16 4 9m 25 7 6m 50 15 2m K1545 Control cable and a 3 0 85 mm2 electrode cable with Twist Mate connector on one end and a stud terminal on the other It is rated at 500 amps 60 duty cycle and is available in lengths o
39. ON Gd ln F 3 Parts Lists P306 Series A 1 INSTALLATION TECHNICAL SPECIFICATIONS Power Feed 10 Wire Drive amp Control Box A 1 H DH OR H DH D D D D RATIO D D RATIO Wire Size Wire Size Low Speed Solid Cored High Speed Solid Cored K1540 1 Power Feed 10 50 800 IPM 025 3 32 in 035 125 in 75 1200 IPM 025 1 16 in 035 5 64 in K1540 2 Wire Drive 1 27 20 3 m m 0 6 2 4 mm 0 9 3 2 mm 2 03 30 5 m m 0 6 1 6 mm 0 9 2 0 mm K1538 1 Power Feed 10 50 800 IPM 025 3 32 in 035 125 in 75 1200 IPM 025 1 16 in 035 5 64 in 2 3 4 Boom Package 1 27 20 3 m m 0 6 2 4 mm 0 9 3 2 mm 2 03 30 5 m m 0 6 1 6 mm 0 9 2 0 mm 5 6 K1541 1 Power Feed 10 50 800 IPM 025 3 32 in 035 125 in 75 1200 IPM 025 1 16 in 035 5 64 in K1541 2 Bench Model 1 27 20 3 m m 0 6 2 4 mm 0 9 3 2 mm 2 03 30 5 m m 0 6 1 6 mm 0 9 2 0 mm Drive and Control Box CONTROL BOX WIRE DRIVE AND COMPLETE UNITS SPEC TYPE INPUT POWER PHYSICAL SIZE TEMPERATURE RATING Dimensions Height Width Depth Weight Operating Storage K1539 1 2 Power 40 VDC 13 0 8 50 4 0 8 5 Lbs Control Feed 10 330 mm 215 105 3 8 Kg Control Only Box 1540 1 2 Power 40 VDC 7 6 12 9 18 7 30 L
40. PANEL LARGE PANEL The MX2 Panel provides a selection of four Power Source modes In addition it provides for the adjustment of the following parameters preflow run in arc control burnback postflow and spot time Descriptions Indicator Lights Extra bright red LED s for viewing at almost any angle Always indicate the mode and active parameter being displayed Display Extra bright 3 1 2 digit 56 14 2 mm charac ter height red LED display for viewing at almost any angle Displays the value or status of the active parame ter CV MIG CV FLUX CORED CC STICK CRISP CC STICK SOFT Available Modes Due to the nature of the system the following feature is required for safety reasons upon entering any constant current CC mode the right encoder labeled Volts Trim on the Display Control Panel acts as a soft con tactor switch The encoder knob must be turned Clock Wise at least 45 to activate the output turning Counter Clock Wise 45 deactivates the output This prevents the output from inadvertently becoming hot when scrolling through the weld modes The exception to this rule is when the weld mode is entered by a change in procedure using a memory panel such as the K1542 9 Memory Dual Procedure panel In this case the state of the contactor is recalled as it was left when the proce dure was exited In the CC modes the output current is set by the Amps control and the Volts Trim adjustment has no
41. SSEMBLIES Available Cable Assemblies K1543 Control cable only Consists of a 5 conductor control cable with a 5 pin control cable plug without electrode cable and is available in lengths of 8 2 4m 16 4 9m 25 7 6m 50 15 2m and 100 30 5m K1544 Consists of a 5 conductor control cable with a 5 pin control cable plug and a 4 0 electrode cable It is rated at 600 amps 6096 duty cycle and is available in lengths of 8 2 4m 16 4 9m 25 7 6m 50 15 2m K1545 Control cable and a 4 0 85 mm2 electrode cable with Twist Mate connector on one end and a stud terminal on the other It is rated at 500 amps 6096 duty cycle and is available in lengths of 8 2 4m 16 4 9m 25 7 6m 50 15 2m With input power disconnected from the power source install the Control Cable Assemblies per the instruction in INSTALLATION Cable Connections POWER FEED 10 LINCOLN C 8 ACCESSORIES K1548 1 LINC NET RECEPTACLE KIT INPUT AND OUTPUT LINC NET RECEPTACLE OUTPUT Optional Output Connector Installation into the Control Box Cabinet and or into the Feeder Head Enclosure Control Box Cabinet Procedure 1 2 Turn off power Remove the screws from the front of the lower and middle option panels of the User Interface cabinet Tilt the option panels away from the front opening of the Control Box cabinet If the option panel has an electrical connector disconnect it from the main printed ci
42. STALLATION GUIDELINES Installation or removal of any panel can be done with only a Phillips screwdriver after the system power is turned off To remove a panel remove the two screws holding it in place remove the push on chassis ground wire and remove the harness connection to the Control Box main PC board To install any panel reverse that process Turn power back on when com plete option panels are only recognized at power up Do not install panels with the power on Note that removal or installation of any panel may also require the removal of the other panel in order to have easy access to the PC board connectors Detailed installa tion instructions are shipped with each option panel BOOM AND BENCH CONVERSIONS The modular design of these feeders allows them to be converted from bench to boom models or vise versa Some additional parts are required to make this conversion Materials Required for bench to boom conversion K1548 1 box Linc Net receptacles installs in control K1543 Length Linc Net Control Cable Control cable between control box and wire drive Materials Required for boom to bench conversion L10286 1 Wire Reel Stand POWER FEED 10 LINCOLN B 1 OPERATION B 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can 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 w
43. T UP CONTROLS DESCRIPTION Certain large option panels can modify the set up parameters Preflow Run In Arc Control Burnback Postflow and Crater The meaning of those parame ters and their maximum and minimum values follows Preflow Time delay after the trigger is pulled but before weld starts during which shielding gas flows Weld start is defined as the time when both the power source is energized and the Wire Drive begins feeding wire Adjustable from 0 0 Off to 2 5 seconds in 0 15 increments Run In Wire feed speed during arc starting Wire Drive will feed wire at the Run In speed for one sec ond or until weld current flows Low speed gear range Off Run In speed equals weld wire feed speed or adjustable from 50 to 150 IPM 1 25 to 3 80 MPM High speed gear range Off Run In speed equals weld wire feed speed or adjustable from 75 to 150 IPM 2 00 to 3 80 MPM NOTE Run In settings over 150 IPM produce strange display values used for troubleshooting and service If encountered reset Run In to 150 IPM or less Arc Control Unitless characteristic also known as Inductance or Wave Control Allows operator to vary the arc characteristics from soft to harsh in all weld modes Adjustable from 10 0 to 10 0 in increments of 0 1 Off 0 0 is nominal Burnback Time delay after the trigger is released during which the power source remains energized but the Wire Drive stops feeding wire Adjustable from 0 00 Of
44. TIC FIELDS 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 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 ihe 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
45. ad Follow the installation instructions includ ed in the kit Water cooled guns can be damaged very quickly if they are used even momentarily without water flowing To protect the gun we recommended that a water flow sense kit be installed This will pre vent wire feeding if no water flow is present WIRE FEED SHUT DOWN CIRCUIT OPTIONAL This circuit is intended to be used as a means of stop ping wire feeding in the event that the water cooler for a water cooled gun is not turned on Water cooled guns can be damaged very quickly if they are used even momentarily without water flowing A Lincoln K1536 1 flow sensor kit is available for this purpose The K1536 1 has two control leads coming from the unit that become electrically common when water is flowing The 25 inch tab terminals of leads 570 and 572 inside the feed head case are disconnected from each other Then the flow sensor control wires are connected to leads 570 and 572 Refer to the instruc tions that come with flow sensor kit for detailed instal lation instructions POWER FEED 10 LINCOLN A 14 OPTIONAL FEATURES INSTALLATION A number of Optional Features are available for use with Power Feed 10 Some Installation information is provided in this section REFER TO THE INSTRUC TIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLA TION OPTIONAL PANELS FOR CONTROL BOX All optional panels for the control box are described in the AC
46. appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page EIER E Section A Technical Specifications ss A 1 Safety 5 mend 2 Mounting the Wire Drive Unit sisi A 2 Boom Mounting of Wire Drive is A 2 Electrode 558 58 23 EE A 2 Mounting the Control Box and Receptacle Configuration 2 A 2 Separating the Control Box from the Wire Drive Bench Model Only A 2 Mounting the Control Box Boom or Separated Bench Models A 3 Determining Receptacle Configuration A 3 Mounting on Power is A 3 Cables mc A 3 Control Cable Connections su A 3 Control Cable Specifications A 4 Available Cable amenant A 4 Electrode Cable Connections A 4 Work Cable Connections A 5 Wire Drive Gear Ratio High or Low Speed A 5 Selecting the Proper Gear Ratio issus A 5 Changing the Wire Drive alio ctetur ere te tte te ie aa trente A 5 DIP Switch Setup A 7 Setting DIP Switches the Control Box and Wire Drive A 7 thru A 10 Wire Feed Drive Roll Kis ir t eene te bete eter tr o pera en ege A 11 Procedure to Install Drive Rolls and Wire Guides A 11 Gun and Cable
47. ar to the feeding direction 19 Loosen the retaining screw which is also accessed from bottom of feeder using a 3 16 Allen wrench Continue to loosen the screw until the feedplate can be easily pulled off of the wire feeder POWER FEED 10 LINCOLN E 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 SYMPTOMS 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 possibili ties that may contribute to the machine Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact you local Lincoln Authorized Field Service Facility If you do not u
48. are fault Contact your Local Authorized erable hardware fault Contact your Local Lincoln Field Service Facility Authorized Lincoln Field Service Facility Green LED ON System normal and functional System normal and functional and steady Normal Blinking LED Each illumination should exist for 0 5 seconds Fast Blinking LED Each illumination should exist for 0 1 seconds POWER FEED 10 LINCOLN ACCESSORIES TABLE C 1 DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4 Roll DH Drive 4 Driven Solid Steel Electrode 0 023 0 025 0 6 mm 0 030 0 8 mm 0 035 0 9 mm 0 040 1 0 mm 0 040 1 0 mm 0 045 1 2 mm 0 052 1 4 mm 1 16 1 6 mm 5 64 2 0 mm 3 32 2 4 mm Cored Electrode 0 030 0 8 mm 0 035 0 9 mm 0 040 1 0 mm 0 045 1 2 mm 0 052 1 4 mm 1 16 1 6 mm 0 068 1 7 mm 5 64 2 0 mm 3 32 2 4 mm 7 64 Lincore Hard Facing 2 8mm 7 64 2 8mm 120 3 0mm Aluminum Electrode 0 035 0 9 mm 0 040 1 0 mm 3 64 1 2 mm 1 16 1 6 mm 3 32 2 2 mm POWER FEED 10 LINCOLN KP1505 0305 KP1505 0305 KP1505 0355 1505 0405 1505 0455 1505 0455 1505 0525 1505 1 165 KP1505 5 64 KP1505 3 32 KP1505 035C KP1505 035C KP1505 045C KP1505 045C KP1505 052C KP1505 1 16C KP1505 068 KP1505 5 64 KP1505 3 32 KP1505 7 64H KP1505 7 64 KP1505 120
49. at the first component in the system the Power Wave 455 has an output receptacle The last compo nent in the system the Control Box has an input receptacle The component in between the Wire Drive has both an input and output receptacle A Control Box can be mounted to the front of a Power Wave 455 When mounting a Control Box removed from a bench feeder no receptacles are required all connections are internal When mounting a Control Box configured as part of a boom system both input and output receptacles are already installed in the Control Box the receptacles do not get used The wiring harness from either J1 or J2 the signals are identical must be disconnected from the harness on the back of one of the receptacles internally This open connector is then used during mounting to the Power Wave 455 MOUNTING ON POWER SOURCE Complete instructions for mounting a Control Box to the front of a Power Wave 455 are included in the Power Wave 455 Operator s manual 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 a con trol cable The Power Wave Power Feed Wire Feeders offer flexibility in the connection of system components This system uses the same type of control cable between all of the system components Connections can be daisy chained from one system compone
50. atches into place Attach the chassis wire if equipped to the back of the new panel 4 Slide the new panel through the opening taking care not to damage the connections and the print ed circuit board on the back 5 Align the screw holes replace the two screws and tighten K1542 9 DUAL PROCEDURE MEMORY PANEL SMALL PANEL Note This panel will function with 524004 3 and high er Control Box Software only The Dual Procedure Memory panel provides for the selection of either of two procedures or a gun switch for remote selection of the procedure In addition there are six permanent memory storage locations for saving commonly used procedures Procedures A and B are soft type memories that record any changes made to them The six memory locations are hard or more permanent type memories Any changes made must be consciously saved back to them Furthermore each memory contains only one proce dure therefore any combination of memories may be recalled to procedure A and B Descriptions Indicator Lights Extra bright red LED s for viewing at almost any angle Always indicate the procedure also indicate active memory and save mode if applicable Switches Discreet PC board mounted switches UL and CSA approved with an IEC rating of protection class IP67 Switch Covers Heavy duty switch covers of silicone rubber providing a high degree of protection from heat and dust Covers are designed to be individually fie
51. ation Sets acceleration rate for wire drive see below Acceleration LSB Sets acceleration rate for wire drive see below Note the factory shipped settings for all of the S1 and S2 switches is OFF POWER FEED 10 LINCOLN A 8 INSTALLATION A 8 S1 DIP Switch Bank on Control Box Motherboard For software version S24004 2 only 1 US 4 Step Trigger Logic Euro 4 Step Trigger Logic 2 WFS Display inches minute WFS Display meters minute 3 Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing Left Display is actual weld current when weld current is flowing CC modes override this switch regardless of position Left Display is always preset weld cur rent when weld current is not flowing and actual weld current when weld current is flowing If any option containing a Run in setting is connected to the motherboard it automatically overrides this switch regardless of position Sets acceleration rate for wire drive see below Acceleration LSB Sets acceleration rate for wire drive see below Note the factory shipped settings for all of the S1 and S2 switches is OFF MSB Most Significant Bit or Byte This is the bit in a binary number or DIP switch bank that is furthest to the left LSB Least Significant Bit or Byte This is the bit in a binary number or DIP switch bank that is furthest to the right POWER FEED 10 LINCOLN A 9 INSTALLATION A 9 S1 DIP Switch Bank on Cont
52. bs Wire Feed 10 195 mm 325 mm 345 mm 13 6 Kg Drive Wire Only Drive 40 C 40 C to to K1541 1 2 Power 40 VDC 18 5 13 5 30 5 62 Lbs 20 C 40 C Bench Feed 10 470 mm 345 mm 775 mm 28 1 Kg Model Bench Model FeederA Drive and Control Box Also part of 15384 Boom package and 1541 Bench Feeder A Dimensions do not include wire reel For Control Box and wire drive dimensions and weights see individual component listings POWER FEED 10 LINCOLN 2 INSTALLATION A 2 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill Only qualified personnel should per form 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 work ing on this equipment Do not touch electrically hot parts Always connect the Power Wave grounding lug located inside the reconnect input access door to a proper safety Earth ground MOUNTING THE WIRE DRIVE UNIT BOOM MOUNTING OF WIRE DRIVE UNIT Mount the wire drive unit by means of the 4 holes in the bottom of the wire drive case See Figure A 1 The gearbox assembly is electrically hot when the gun trigger is pressed Therefore make certain the gearbox does not come in contact with the structure on which the unit is mounted The
53. ce wire drive etc The left knob display is labeled WFS AMPS wire feed speed amps In non synergic modes the WFS control changes the wire feed speed according to the desired procedure In synergic welding modes syner gic CV pulse GMAW WFS is the dominant control parameter controlling all other variables POWER FEED 10 LINCOLN B 2 OPERATION B 2 The user adjusts WFS according to factors such as weld size penetration requirements heat input etc The power source then uses the WFS setting to adjust its output characteristics output voltage output cur rent according to pre programmed settings contained in the power source In constant current modes arc gouging stick TIG this control adjusts the output cur rent in amps An LED lights to inform the user which function WFS or amps is active This display can be either English or metric units Further this display can be set up to display either WFS or amps when using wire welding modes See SETTING DIP SWITCHES in the INSTALLATION section The right knob is labeled VOLTS TRIM In constant voltage modes synergic CV standard CV the control adjusts the welding voltage In pulse synergic welding modes pulse GMAW only the user can change the Trim setting to adjust the arc length It is adjustable from 0 50 to 1 50 A Trim setting of 1 00 means than no adjustments will be made to the preset arc lengths and is optimum for most conditions An LED lights to
54. ch is rated to be 60 SCFH 28 l min 2 Adjust gas supply flow rate for a level higher than will be required then adjust Gas Guard flow adjusting Key counterclockwise to the desired gas flow rate POWER FEED 10 LINCOLN B 10 MAKING A WELD 1 Use only a network compatible power source 2 Properly connect the electrode and work leads for the correct electrode polarity 3 Set all desired parameters such as trigger logic Run in Speed Acceleration Electrode polarity etc per DIP SWITCH SETUP in the INSTALLATION section E Set 2 step 4 step switch on wire drive to desired mode of operation Refer to 2 step 4 step switch operation in this section 5 Select Weld Mode Refer to Control Box Operation in this section 2 Use Control Select switches increment decrement switches and encoder knobs to set desired para meters for weld depending on what options are installed Refer to Control Box Operation in this section e Feed the electrode through the gun and cable and then cut the electrode within approximately 38 9 5 mm of the end of the contact tip for solid wire and within approximately 75 19mm of the exten sion guide for cored wire 8 Connect work cable to metal to be welded Work cable must make good electrical contact to the work The work must also be grounded as stated in Arc Welding Safety Precautions WARNING When using an Open Arc process 2 it is necessary
55. ders 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 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
56. e Power Source modes The upper position selects the generic CV MIG mode from the power source the middle position selects the CV FLUX CORED mode and the lower position selects the CC STICK GOUGE mode Arc control is accomplished through the use of the ARC CONTROL potentiometer The arc control value is actually a trim with zero being the nominal and the scale ranging from 10 to 10 Preflow postflow and spot time default to zero or off Run in defaults to the minimum value or weld speed depending on the position of its associated dip switch Burn back defaults to the on board trimmer adjustment NOTE Due to the nature of fixed position switches potentiometers and default values this option does not allow the mode arc control timers or Burn back values to be included in dual pro cedure or memory information They are over ridden by the fixed values CC STICK GOUGE Mode Selecting the CC STICK GOUGE mode on this panel automatically energizes the output terminals on the power source making the power source immediately ready to weld In the CC modes the output current is set by the Amps control and the Volts Trim adjust ment has no effect in this mode In this mode the Arc Control adjusts the arc force Increasing the Arc Control setting increases the arc force making the arc more harsh but less likely to stick Decreasing the Arc Control setting decreases the arc force making the arc softer and smoother Constant Vo
57. e avail able The bus may be being used to pro gram another component The LED s of the power source and the component being programmed will be solid green Indicates a recoverable communication fault most likely caused by one of the following More than one control box UI in the group All control boxes in the group will be blinking red No control box UI in the group All nodes in the group will be blinking red More than one node of the same equip ment type has the same group and feed head FH numbers All these nodes will be blinking red feed head DIP switches may be set to zero The nodes with DIP switches set to zero will be blinking red The node bus may be off Indicates a recoverable hardware fault such as over temperature overload shutdown etc Could also be an open shutdown circuit at the feed head leads 570 572 with tab termi nals typically used for water flow shutdown switches B 12 OPERATION B 12 STATUS LIGHT STATES CON T LED State Power Source LED LED on any other nodes components Wire Feeder Control Box Etc Red LED blinking Power source needs to be reprogrammed System component node needs to be at a fast rate Contact your Local Authorized Lincoln Field reprogrammed Contact your Local Service Facility Authorized Lincoln Field Service Facility Red LED ON and Power source has a non recoverable hard System component node has a non recov steady w
58. e drive feedplate to provide for use of guns with Fast Mate or European style gun connections This K489 7 will handle both standard Fast Mate and Dual Schedule Fast Mate guns Another way to connect a gun with a Fast Mate or European style gun connector to the Power Feed 10 is to use the K489 2 Fast Mate adapter kit Installation of this adapter also requires a K1500 1 gun connector See Gun Adapters in ACCES SORIES section POWER FEED 10 LINCOLN A 12 Magnum 200 300 400 Guns The easiest and least expensive way to use Magnum 200 300 400 guns with the Power Feed 10 wire feeder is to order them with the K466 10 connector kit or to buy a completely assembled Magnum gun having the K466 10 connector such as the K497 21 dedicated Magnum 400 Magnum 550 Guns The easiest and least expensive way to use the Magnum 550 guns with Power Feed 10 wire feeders is to order the gun with the K613 7 connector kit and install a K1500 3 gun connection kit to the wire feeder Lincoln Innershield and Sub Arc Guns All of these guns can be connected to the Power Feed by using the K1500 1 Adapter Kit Lincoln Fume Extraction Guns The K556 250XA and K566 400XA guns require that K489 2 Fast Mate adapter kit be installed Installation of this adapter also requires a K1500 1 gun connector kit The K206 K289 and K309 require only the installa tion of a K1500 1 connector in the Power Feed wire feeder N
59. e solid green on both CB and feed head boards Possible problem with current sensor electronics in power source Check power source man ual to trouble shoot current sensor electronics 67 and or 21 voltage sense leads may have intermittent or poor con nections Check Possible problem with power source electronics Defective gas purge switch or feed head board Check continuity with gas purge switch held down across J1 pins 3 and 5 Release purge switch and note there should be no continuity now If either of these fail the problem is either in the gas purge switch or harnessing If no failure replace feed head board Defective cold feed switch or feed head PC board Check continuity with cold feed switch held up across plug pins 3 and 4 of J1 Release the cold inch switch and note that there should be no conti nuity now If either of these fail the problem is either in the purge switch or harnessing If continuity O K replace feed head board If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10 LINCOLN TROUBLESHOOTING E 7
60. e spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY WELDING and CUTTING lt gt SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautio
61. e tight metal to metal electrical contact The Electrode cable should be sized according to the specifications given in the work cable connections section WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length per the following table between the proper output termi nal 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 bundle the electrode and ground cables together where practical and do not coil excess cable Minimum work and electrode cables sizes are as fol lows Current 60 Duty Cycle Minimum Copper Work Cable Size AWG Up to 100 ft Length 30m 400 Amps 2 0 67 mm 500 Amps 3 0 85 mm 600 Amps 3 0 85 mm When using an inverter type power source use the largest welding electrode and ground cables that are practical At least 2 0 copper wire even if the aver age 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 WIRE DRIVE GEAR RATIO HIGH OR LOW SPEED The speed range capability and drive torque of the Power Feed 10 wire drive can be easily and quickly changed by
62. ection for roll chang ing instructions Wire Reel Mounting Readi Reels and 10 through 301b 4 5 14kg Spools No routine maintenance required Avoiding Wire Feeding Problems Wire feeding problems can be avoided by observing the following gun handling and feeder set up proce dures a Do not kink or pull cable around sharp corners b Keep the electrode cable as straight as possible when welding or loading electrode through cable c Do not allow dolly wheels or trucks to run over cables d Keep cable clean by following maintenance instructions e Use only clean rust free electrode The Lincoln electrodes have proper surface lubrication f Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed g Do not use excessive wire spindle brake settings h Use proper drive rolls wire guides and drive roll pressure settings Periodic Maintenance Wire Drive Motor and Gearbox Every year inspect the gearbox and coat the gear teeth with a moly disulfide filled grease Do not use graphite grease Every six months check the motor brushes Replace them if they are less than 1 4 long Gun and Cable Maintenance See appropriate Operator s Manual Procedure for Removing Feedplate from Wire Feeder 1 Loosen the clamping collar screw using a 3 16 Allen wrench The clamping collar screw is accessed from the bottom of the feedplate It is the screw which is perpendicul
63. ector style guns connect gun to gun connector making sure all pins and gas tube line up with appropri ate holes in connector Tighten gun by turning large nut on gun clockwise d For GMA Gun Cables with separate gas fittings connect the 3 16 1 0 gas hose from the wire drive unit to the gun cable barbed fitting e For water cooled guns see WATER CONNEC TIONS in this section POWER FEED 10 LINCOLN A 13 GMAW SHIELDING GAS WARNING CYLINDER may explode if damaged Keep cylinder upright and chained to support Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live elec trical circuits BUILDUP OF SHIELDING GAS may a harm health or kill Shut off shielding gas supply when ms SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUBLISHED BY THE AMERICAN WELDING SOCIETY Customer must provide a cylinder of shielding gas a pressure regulator a flow control valve and a hose from the flow valve to the gas inlet fitting of the wire drive unit Connect a supply hose from the gas cylinder flow valve outlet to the 5 8 18 female inert gas fitting on the back panel of the wire drive or if used on the inlet of the Gas Guard regulator See Below Gas Guard Regulator The Gas Guard Regulator is an optional accessory K659
64. effect in this mode In this mode the Arc Control adjusts the arc force Increasing the Arc Control setting increases the arc force making the arc more harsh but less likely to stick Decreasing the Arc Control setting decreases the arc force making the arc softer and smoother Parameter Ranges PREFLOW 0 0 to 2 5 seconds 0 1 sec increments RUN IN Low Range 50 to 150 IPM 1 25 to 3 80 MPM High Range 75 to 150 IPM 2 00 to 3 80 MPM ARC CONTROL Trim 10 0 to 410 0 0 is nominal BURN BACK 0 0 to 0 25 sec 0 01 sec increments POSTFLOW 0 0 to 2 5 sec 0 1 sec increments CRATER ON or OFF Functions in 4 step trigger mode only Mode Selection The MODE SELECT switch is a momentary large bat three position toggle switch that defaults to the center off position Moving the switch bat up advances the mode indicator in the upward direction down advances it in the downward direction Holding the switch in either direction will result in the indicator advancing at a high rate of speed in that direction until the switch is released When the indicator reaches its upper or lower limit advancing ceases until the direction of the switch is changed Parameter Selection The PARAMETER SELECT switch is a momentary large bat three position toggle switch that defaults to the center off position Moving the switch bat up advances the parameter indicator in the upward direction down advances it in the downwa
65. ener eme NN Gear Box Ratio Low Gear Box Ratio High Switch position must match actual gear box ratio of wire drive Note the factory shipped settings for all of the S1 switches is OFF POWER FEED 10 LINCOLN A 11 WIRE FEED DRIVE ROLL KITS NOTE The maximum rated solid and cored wire sizes and selected drive ratios are shown on the SPECIFICATIONS in the front of this sec tion The electrode sizes that can be fed with each roll and guide tube are stenciled on each part Check the kit for proper components Kit specifications can be found in the ACCESSORIES section PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES WARNING ELECTRIC SHOCK can Do not touch electrically live parts such as output terminals or internal wiring When feeding without Power Feed 10 Cold Feed feature 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 this installation Observe all additional Safety Guidelines detailed throughout this manual Drive Roll Kit Installation KP1505 1 Turn OFF Welding Power Source 2 Pull open Pressure Door
66. etting all adjustments and functions on the Power Feed to the desired settings To save the settings to Memory 1 simply hit the Save button its red light will illuminate and then hit the 1 button The settings are now saved in Memory 1 The contents of Memory 1 will not change even if the power is turned off until the next time the Save key and the 1 key are hit in sequence The same proce dure can be applied to each of the other 5 memories If the Save key is hit accidentally simply hit the Save button again its light will go out and the Save func tion will be canceled Note It is not required to load all 6 memories at once nor is it necessary to load them in order Memory can be loaded at any time except when welding Similarly the Save key is not active while the gun trig ger is pulled or while welding POWER FEED 10 LINCOLN 3 OPERATION B 3 Memory has an advanced feature called memory reminder When the Save key is hit the memory reminder function flashes the LED of the most recently used memory so the operator can save procedures in the most recently used memory if desired It is not necessary to save to the most recently used memory the memory reminder function and it s flashing LED can be ignored Memories cannot be changed without using the Save key When slight procedure adjustments are neces sary but there is no desire to permanently save the adjustments to a memory this can be done
67. f to 0 25 seconds in 0 01 second increments Postflow Time delay after burnback is complete during which shielding gas flows Adjustable from 0 0 Off to 10 0 seconds in 0 1 second increments POWER FEED 10 LINCOLN B 5 OPERATION B 5 Crater Used only when welding with the 4 Step trig ger mode Can be set to Off or On When On Adjustments can be made to WFS and Volts Trim on the Control Display panel These settings are then used for cratering when in the 4 Step trigger mode see explanation of 2 Step and 4 Step operation below When Off cratering is not possible CONTROL BOX PC BOARD ADJUSTMENTS The Control Box Mother board provides the capability to adjust some wire feeding parameters as follows Acceleration The motor acceleration can be varied in five steps from slow to fast See Setting DIP Switches in the Control Box section Burnback For the options which cannot adjust the Burnback set up parameter CV G and M panels a PC board adjustment trimmer R5 is provided The range is 0 0 to 0 25 seconds increasing in the clock wise direction This is ignored by options which have the ability to adjust Burnback MX2 and MSP2 pan els Run In For the options which cannot adjust the Run In set up parameter CV G and M panels a PC board DIP switch setting is provided In one position the run in speed will be the minimum Wire Drive WFS At the other setting run in will occur at the same speed as se
68. f 8 2 4m 16 4 9m 25 7 6m 50 15 2m ELECTRODE CABLE CONNECTIONS 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 located beneath the spring loaded output cover near the bottom of the case front For positive porosity application a work lead must be run 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 Excessive voltage drops at the work piece connection often result in unsatisfactory pulse welding perfor mance When negative electrode polarity is required such as in some Innershield applications install as above except reverse the output connections at the power source electrode cable to the negative stud and work cable to the positive stud Change electrode polarity Dip Switch in Feed Head see Dip Switch Setup Section POWER FEED 10 LINCOLN 5 INSTALLATION A 5 Connect the one end of the electrode cable to the power source output terminal of the desired polarity Connect the other end of the electrode cable to the connection bar at the front of the wire drive feed plate using the provided bolt and lockwasher The elec trode cable lug must be against the feed plate Be sure the cable connection bar and gun adapter bush ing all mak
69. g harness and option panel harness if any Feeder Head Enclosure Procedure 1 2 Turn power off Remove the Feeder Head rear access door The Feeder Head cover can be removed to aid instal lation but is not required Remove the plastic plug black from the hole at the right rear of the Feeder Head and store it in the left side of the Feeder Head rear compart ment for future use should the Optional Output Connector be removed Disconnect a printed circuit board connector located at the bottom right corner of the printed circuit board and position it to the left so as to pro vide clear access to the lower right corner of the Feeder Head enclosure Place the Optional Output Connector Amphenol through the hole opened by the two previous steps place from the inside out Rotate the Optional Output Connector so it s aligning key is positioned to the top of the Feeder Head enclo sure Fasten the Optional Output Connector to the back wall of the Control Box cabinet with the four screws provided Secure the choke large circular component of the Optional Output Connector by inserting it s leads into the white nylon clip located near the Optional Output Connector on the floor of the Feeder Head Insert the long choke leads rather than the short leads that run between the choke and the Output Connector Insert the choke leads only The Optional Output Connector has two internal connectors a four p
70. id dle positions which allow the upper two panels to be interchanged Instead of the upper middle and lower panels being large small and large they could be installed in the order small large large This may be done for convenience sake or to take advantage of the Large Security Door option Note The CD panel must be installed in either the middle or the upper position its harness is not long enough to allow installation in the lower position GENERAL PANEL INSTALLATION GUIDELINES Installation or removal of any panel can be done with only a Phillips screwdriver after the system power is turned off To remove a panel remove the two screws holding it in place remove the push on chassis ground wire and remove the harness connection to the Control Box main PC board To install any panel reverse that process Turn power back on when com plete option panels are only recognized at power up Do not install panels with the power on Note that removal or installation of any panel may also require the removal of the other panel in order to have easy access to the PC board connectors Detailed installa tion instructions are shipped with each option panel K1542 5 DUAL PROCEDURE PANEL The Dual Procedure Panel provides a fixed large bat toggle switch or the use of a gun switch for the selec tion of either of two procedures The upper position of the bat switch selects PROCEDURE A while the lower selects PROCEDURE B The middle p
71. ily be converted to a boom feeder RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Feed 10 can be set up in a number of con figurations It is designed to be used for GMAW GMAW P FCAW and SMAW for a variety of materi als including mild steel stainless steel and cored wires RECOMMENDED EQUIPMENT The Power Feed 10 must be used with power sources having digital communication capabilities and 40 VDC auxiliary power The presently available power source is the PowerWave 455 DUTY CYCLE The Power Feed 10 wire feeder is capable of welding at a 10096 duty cycle continuous welding The power source will be the limiting factor in determining system duty cycle capability CONTROL BOX OPERATION The most frequently used Control Box controls and settings are external some features are accessed by internal controls and settings CONTROL BOX PANELS UPPER PANEL CONTROL DISPLAY PANEL REQUIRED Each PF 10 Control box must have a Control Display CD panel This panel consists of adjustment knobs digital displays and a series of indicator lights LEDs There are two knobs each has a 4 digit LED display and a pair of LEDs associated with it Knobs and dis plays have dual functions the LEDs indicate which function at any given time This panel also has a dual color Status LED used to indicate the general health status of the Control Box and its connection to other components in the system power sour
72. in and a single lead connec tor Connect the four pin connector to the unused four pin connector on the printed circuit board Connect the single lead connector to a similar connector found on a lead nearby that branches out of the Feeder Head wiring harness Reconnect the printed circuit board connector that was disconnected earlier Replace the rear access door and Feeder Head cover if removed POWER FEED 10 LINCOLN C9 ACCESSORIES 9 LINC RECEPTACLE INPUT Power Feed Wire Feeder Optional Input Connector Installation into the Control Box Cabinet and Conversion to Fixture Wire Feeder 1 Turn off power 2 Remove the screws from the front of the lower and middle option panels of the Control Box cabi net 3 Tilt the option panels away from the front opening of the Control Box cabinet If the option panel has an electrical connector disconnect it from the main printed circuit board note connection point for re connection later Remove the option panel and set aside 4 Disconnect the connector located at the back wall of the Control Box cabinet 5 Loosen do not remove the four screws located on the back wall of the Control Box cabinet 6 Lift Control Box cabinet off of the four screws loosened above and set on a work surface Re tighten the four screws to secure for future use 7 Remove the plastic plug black from the right hole in the bottom wall of the Control Box cabinet and in
73. in this section WIRE FEED OVERLOAD PROTECTION The wire drive has solid state overload protection of the wire drive motor If the wire drive motor becomes overloaded for an extended period of time the wire drive will issue a shutdown command to the Control Box and force it s status light to blink between green and red The Control Box turns off the power source wire feed and gas solenoid The status light on the wire drive will continue to blink between green and red for about 30 seconds before the wire drive will auto matically reset At that time the wire drive will issue a shutdown over command to the Control Box that will return the system to normal operation The wire drive will force it s status light to solid green Overloads can result from improper tip size liner drive rolls or guide tubes obstructions or bends in the gun cable feeding wire that is larger than the rated capacity of the feeder or any other factors that would impede normal wire feeding See Avoiding Wire Feeding Problems in the MAINTENANCE section POWER FEED 10 LINCOLN B 11 COMPONENT STATUS LIGHTS Each network component has a single status light The light is a bicolor Green Red LED The purpose of the status light is to allow the operator to quickly identify that the system is working properly or if not OPERATION B 11 which component is causing the problem By using the status lights the operator can quickly pinpoint the system
74. in the save mode it s contents are overwritten with the contents of the active procedure This means that the contents of the memory location and the active procedure are now equal and there fore by definition each of their indicators will be lit and the save mode will be exited To exit the save mode without saving depress the save key a second time This feature allows the operator to determine the source of the active procedure s contents without actually overwriting it Installation is as follows 1 Turn off power 2 Remove the two screws from the front of the stan dard or option panel at the location you choose to install your new option middle of the Control Box cabinet Save the screws for re use Unplug the white electrical connector Remove the chas sis wire if equipped from the back of the stan dard or option panel Discard the old panel or save for future use 3 Tilt the new option panel away from the front opening of the Control Box cabinet and plug the white electrical connector into the proper connec tor on the right side of the main printed circuit board 10 pin until the connector latches into place Attach the chassis wire if equipped to the back of the new panel 4 Slide the new panel through the opening taking care not to damage the connections and the print ed circuit board on the back 5 Align the screw holes and tighten Replace the two screws K1543 K1544 AND K1545 INPUT CABLE A
75. inform the user which function volts or trim is active Both displays indicate preset values according to the weld mode selected when not welding Once weld ing begins they switch to displaying actual values At that time the indicator LEDs will flash to signify actual values are being displayed The displays hold the actual values for 5 seconds after a weld is stopped Turning a knob during the hold time shuts off the hold and returns the meters to their preset values The allowable settings are determined by other sys tem components The WFS range for instance is dependent upon the gear range in the Wire Drive and on the welding programs in the Power Wave power source The voltage and current are similarly limited by programs in the Power Wave CONTROL BOX PANELS SMALL OPTIONAL PANELS K1542 5 Dual Procedure Panel This panel provides for setting and manual selection of two procedures with a toggle switch Selection can be done at the panel or through a dual procedure welding gun switch connected to the Wire Drive trig ger receptacle The upper position selects Procedure A while the lower selects Procedure B The middle position selects the Gun Switch in which case the procedure is determined by the dual procedure weld ing gun switch Note When in the Gun Switch mode this option does not have provisions for indicat ing which remotely selected procedure A or B is active To set Procedure A move the switch to
76. ire electrodes It significantly reduces any abrasion to the electrode wire where it enters the feed head This results in even smoother more trouble free operation POWER FEED 10 LINCOLN D 1 MAINTENANCE D 1 MAINTENANCE Safety Precautions 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 Routine Maintenance Drive Rolls and Guide Tubes After feeding every coil of wire inspect the drive roll section Clean it as necessary The driver rolls and Inner Wire Guides are stamped with the wire sizes they will feed If a wire size other than that stamped on the roll s is to be used the roll s and Inner Wire Guides must be changed All drive rolls have two identical grooves The rolls may be flipped over to use the other groove See Procedure to Install Drive Rolls and Wire Guides in the INSTALLATION s
77. it wire guide groove Drive rolls may not be seated properly If all recommended possible areas of Gun cable dirty Clean if neces misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Worn drive roll Field Service Facility Electrode rusty and or dirty Cable frayed or poor solder joint at work or electrode lug Worn nozzle or cable liner Replace if necessary Partially flashed or melted contact tip Replace if necessary Incorrect drive roll pressure Readjust if necessary Improper liner tip or inner outer guides Replace if necessary A 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 10 LINCOLN 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual 2 Variable or hunting arc Wrong size worn and or melted contact tip Replace if neces sary Worn work cable or poor work connection Replace if neces sary Loose electrode or work cable connections Wrong polarity Make sure elec trode polarity is correct for If all recommended possible areas of process being used misadjustment have been checked and the problem persists Contact Gas nozzle extended beyond gun your loca
78. l Lincoln Authorized tip or wire stickout too long while Field Service Facility welding Poor gas shielding on processes requiring gas Check gas flow and mixture 3 Poor arc striking with sticking or a Improper procedures or tech blast offs weld porosity narrow niques See Gas Metal Arc and ropy looking bead or electrode Welding Guide GS 100 stubbing into plate while welding Improper gas shielding Clean gas nozzle Make certain that gas diffuser is not empty or turned off Make certain gas flow rate is proper Remove gun liner and check rub ber seal for any sign of deteriora tion or damage Be sure set screw in connector block is in place and tightened against the liner bushing 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 10 LINCOLN E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual 4 Tip seizes in diffuser a Tip overheating due to prolonged or excessive high current and or duty cycle welding Note A light application of high temperature antiseize lubri cant such as Lincoln E2067 Graphite Grease may be applied to tip of threads Unit shuts off while welding or Wire feed shut down circuit attempting to weld status light
79. l deactivate output A 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 10 LINCOLN 8 Jequunu epoo 1ueuudinbe eu 10 2911S eidel si eui j sjeued 21nsojous y euo uo y LL peised s 10 siy Aq 40 eq jou 10 S SIUL ILON 988011 3LIHM M Xovi8 8 10H1NOO ONIQOO 40709 AVI NOILO3NNOO SISSVHO y 716913 334 SIOAWAS 199119573 IVNOILdO S3NIHOVIN HOlHd 96901 3002 NO 1N3S3Hd 38 LON AYN 3191419034 306 109110 13 0 1 1N3NOd OO Od 30 3903 SY 30N3n03s ONIH3EINDN ALIAVO TYNOLLIGAY ONIBIM S NOLLdO 1VNOILdO JHL 395 S3HIM NMOHS JHL JO TIY LON AYN GATIYLSNI NOLLdO JHL TN 310v1d3o3u 310V14303 13 0 1 IVNOILdO 430334 OL ON INANI 13 008 03140 av31 8 300H1VO SN31 031 30 3903 1973 1838 Nid en HOLO3NNOO 40 3015 0931
80. ld replaceable in the unlikely event that one gets dam aged Dual Procedure Selection The procedure switch is used to scroll the indicator to select PROCEDURE A PROCEDURE B or the GUN switch When the GUN switch is selected the proce dure is determined by the position of the switch locat ed at the gun Under this condition indicators will show that the gun switch has been selected and also which procedure the gun switch is requesting Memory Selection RECALL When a memory key is depressed its indi cator comes on and its contents are copied to the active procedure As long as no changes are made to the contents of that procedure the memory indicator will be on anytime that procedure is active This indi cates that their contents are the same Any change to that procedure will cause the memory indicator to go off indicating that they are no longer equal POWER FEED 10 LINCOLN C7 ACCESSORIES C7 SAVE The save mode allows hard memories to be changed Pressing the SAVE key will light the save indicator and enter the save mode In the save mode the indicator for the memory that was the source of the active procedure s contents will blink whether their contents are still equal or not This feature allows the user to choose to save an active procedure back to its source or some other location To complete the save transaction requires the selec tion of one of the memory keys When the memory key is pressed
81. low holes to line up further loosen the screw on right face of feed plate Remove the small gear from the output shaft Lightly cover the output shaft with engine oil or equivalent Install gear onto output shaft and secure with flat washer lock washer and Phillips head screw which were previously removed Tighten the screw on lower right face of feed plate Re attach feed plate to wire feeder if removed in Step 2 Feed plate will be rotated out of position due to the gear change Adjust the angle of the feed plate per the instructions above Set the High Low switch code on Wire Drive PC board as follows a Remove the cover from the back of the feed lt POWER FEED 10 LINCOLN head 2 screws Locate the 8 position DIP switch near the top edge of the PC board centered left to right The setting will be made on the right most switch S8 Using a pencil or other small object slide the switch down to the O position when the low speed gear is installed Conversely slide the switch up to the 1 position when the high speed gear is installed Refer to Figure A 3 Replace the cover and screws The PC board will read the switch at power up automati cally adjusting all control parameters for the speed range selected 7 INSTALLATION A 7 DIP SWITCH SETUP ON S 1 2 3 4 5 6 7 8
82. lower limit outside of the minimum and maximum wire feed speed of the Wire Drive nor above the upper limit Turn the system power off Return S2 6 to off To adjust the upper limit set S2 7 to on Turn the power on and adjust the WFS Amps and Volts Trim knobs to the desired upper limits Note You will not be able to adjust the upper limit outside of the mini mum and maximum wire feed speed of the Wire Drive nor below the lower limit Turn the system power off Return S2 7 to off If a Dual Procedure panel is installed repeat the above procedure with the Procedure B selected When done attach the Control Display panel to the Control Box The machine is now ready for normal operation with the new limits CONTROL BOX USING OPERATING LIMITS Once set limits apply to all weld modes Limiting Procedure A to 200 to 300 inches per minute for example limits the ability of the operator to adjust his WFS in pulse CV and FCAW weld modes Limiting the Volts to 23 0 to 24 5 would limit the ability of the operator to adjust his Volts in synergic and non syner gic CV modes Procedure B could be set up with dif ferent limits Limits are absolute they will override values stored in the memories Note that limits do not apply to set up parameters such a Preflow and Arc Control POWER FEED 10 LINCOLN B 6 OPERATION B 6 OPERATION WITH PREVIOUS SOFTWARE VERSION The operation of the previous Control Box software version S2400
83. ltage CV Weld CV MIG CV Flux Cored Procedures When in this mode the Arc Control adjusts the induc tance This adjustment is often referred to as pinch Inductance is inversely proportional to pinch Increasing the Arc Control setting decreases the inductance which results in the arc getting colder and pinched tighter Decreasing the Arc Control setting increases the inductance which results in the arc get ting wider reduced pinch Installation is as follows 1 Turn off power 2 Remove the two screws from the front of the stan dard or option panel at the location you choose to install your new option bottom of the Control Box cabinet Save the screws for re use Unplug the white electrical connector Remove the chas sis wire if equipped from the back of the stan dard or option panel Discard the old panel or save for future use Tilt the new option panel away from the front opening of the Control Box cabinet and plug the white electrical connector into the proper connec tor 12 pin on the right side of the main printed circuit board until the connector latches into place Attach the chassis wire if equipped to the back of the new panel Slide the new panel through the opening taking care not to damage the connections and the print ed circuit board on the back Align the screw holes replace the two screws and tighten POWER FEED 10 LINCOLN 8 ACCESSORIES 6 4 1542 11 2
84. m the contact to the work piece The Power Wave is optimized for use with a 75 stick out The adaptive behavior is programmed to support a stickout range from 5 to 1 25 In the low and high end of the wire feed speed ranges of most processes the adaptive behavior may be restricted This is a physical restriction due to reaching the edge of the operating range for the process The Arc Control adjustment allows the pulse frequen cy to be varied Increasing the Arc control causes the frequency setting to increase while decreasing the Arc Control causes the frequency to decrease Varying the Arc Control and hence the pulse fre quency affects the droplet transfer and allows fine tuning for different welding positions Crater Fill operation is covered in the WIRE DRIVE OPERATIONS section Installation is as follows 1 Turn off power 2 Remove the two screws from the front of the stan dard or option panel at the location you choose to install your new option bottom of the Control Box cabinet Save the screws for re use Unplug the white electrical connector Remove the chas sis wire if equipped from the back of the stan dard or option panel Discard the old panel or save for future use 3 Tilt the new option panel away from the front opening of the Control Box cabinet and plug the white electrical connector into the proper connec tor 12 pin on the right side of the main printed circuit board until the connector l
85. mpany 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 instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement
86. n this mode the Arc Control adjusts the arc force Increasing the Arc Control set ting increases the arc force making the arc more harsh but less likely to stick Decreasing the Arc Control setting decreases the arc force making the arc softer and smoother Parameter Selection The PARAMETER SELECT switch is a momentary large bat three position toggle switch that defaults to the center off position Moving the switch bat up advances the parameter indicator in the upward direc tion down advances it in the downward direction Holding the switch in either direction will result in the indicator advancing at a high rate of speed in that direction until the switch is released When the indica tor reaches its upper or lower limit advancing ceases until the direction of the switch is changed Parameter Adjustment The value of the active parameter as defined by the parameter indicator is displayed on the parameter display The PARAMETER SET switch is a momen tary large bat three position toggle switch that defaults to the center off position Moving the switch bat up advances the displayed value in the positive direction down advances it in the negative direction Holding the switch in either direction will result in the displayed value advancing at a high rate of speed in that direc tion until the switch is released When the indicator reaches its upper or lower limit advancing ceases until the direction of the switch is changed
87. nd 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 5 f AUG 06 LINCOLN material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 2 5 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 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 th
88. nd the Release Bar on the Retaining Collar pops up and that the collar retainers fully engage the retaining groove on the spindle SPINNER NUT SPRING LOADED ARM REEL FIGURE B 2 POWER FEED 10 LINCOLN 9 OPERATION B 9 FEEDING ELECTRODE AND BRAKE ADJUSTMENT 1 Turn the Reel or spool until the free end of the electrode is accessible 2 While tightly holding the electrode cut off the bent end and straighten the first 6 150 mm Cut off the first 1 25 mm If the electrode is not proper ly straightened it may not feed or may jam causing a birdnest 23 Insert the free end through the incoming guide tube Press the Cold Inch key or the Cold Feed Mode gun trigger and push the electrode into the drive roll A WARNING When feeding with the gun trigger unless COLD FEED trigger mode is selected the electrode and drive mechanism are always HOT to work and ground and could remain HOT several seconds after the gun trigger is released 5 Feed the electrode through the gun 6 Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with little or no overrun when wire feeding is stopped Do not overtighten DRIVE ROLL PRESSURE SETTING The Power Feed 10 pressure is factory pre set to about position 2 as shown on the pressure indicator on the front of the feedplate door This is an appro
89. nderstand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility 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 these trouble shooting procedures 0 Observe all additional Safety Guidelines detailed throughout this 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 10 LINCOLN 8 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual 1 Rough wire feeding or wire notla Gun cable kinked and or twisted feeding but drive rolls are turning Wire jammed in gun and cable Check for mechanical restrictions in feeding path Check for current position of drive rolls Relative to spl
90. ng spring tab 7 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 8 Slide cage all the way onto the adapter until the retaining spring pops up fully CAUTION Check to be sure the Retaining Spring has fully returned to the locking position and has SECURELY locked the Readi Reel Cage in place Retaining Spring must rest on the cage not the welding elec trode 9 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle POWER FEED 10 LINCOLN 8 OPERATION 2 IN OD SPINDLE ADAPTER RETAINING SPRING BRAKE HOLDING PIN RETAINING COLLAR GROOVES READI REEL INSIDE CAGE WIRES RELEASE BAR FIGURE B 1 To Mount 10 to 44 Lb 4 5 20 kg Spools 12 300 mm Diameter or 14Lb 6 Kg Innershield Coils The Spindle should be located in the LOWER mounting hole For 8 200 mm spools a K468 spindle adapter must first be slipped onto spindle For 13 14 Ib 6 Kg Innershield coils a K435 Coil Adapter must be used 1 Depress the Release Bar on the Retaining Collar and remove it from the spindle ZS Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the back side of the spool Be certain the wire comes off the reel in a direction so as t
91. ns 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 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
92. nt to another Components can be connected in any order as long as the proper input and output receptacles are present See MOUNTING CONTROL BOX AND RECEPTACLE CONFIGURATION for details NOTE The maximum cable length between any two pieces of equipment is 250 POWER FEED 10 LINCOLN A 4 INSTALLATION 4 Typical Bench Feeder Connection Control cable is connected from the Power Wave 455 output receptacle to the input receptacle on the back of the Wire Drive Typical Boom Feeder Connection One control cable is connected from the Power Wave 455 output receptacle to the Control Box input recep tacle second control cable is connected from the Control Box output receptacle to the input receptacle on the back of the Wire Drive Multiple Wire Drive Connection For proper multiple wire drive connections and DIP switch settings contact the Lincoln Electric Company Customer Service Department 1 800 833 WELD Non Typical Boom Feeder Connection One control cable is connected from the Power Wave 455 output receptacle to the the input receptacle on the back of the Wire Drive A second control cable is connected from the output receptacle on the back of the Wire Drive to the Control Box input receptacle Control Box Mounted on Power Wave 455 One control cable is connected from the Power Wave 455 output receptacle to the input receptacle on the back of the Wire Drive See CONTROL AND ELECTRODE CABLE INSTAL LATIO
93. o de reel from the bottom of the coil Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle To Mount a 50 60 Lb 22 7 27 2 kg Coil Using K1504 1 Coil Reel For 50 60 Ib Readi Reels a K438 Readi Reel Adapter must be used The Spindle must be located in the UPPER mounting hole 1 With the K1504 1 Coil Reel mounted on to the 2 51 mm spindle or with reel laying flat on the floor loosen the spinner nut and remove the reel cover See Figure B 2 2 Before cutting the tie wires place the coil of elec B 8 trode on the reel so it unwinds from the bottom as the reel rotates S Tighten the spinner nut against the reel cover as much as possible by hand using the reel cover spokes for leverage DO NOT hammer on the spinner nut arms 4 Cut and remove only the tie wire holding the free end of the coil Hook the free end around the rim of the reel cover and secure it by wrapping it around Cut and remove the remaining tie wires CAUTION Always be sure the free end of the coil is securely 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 so it must either be untangled or discarded 5 Be sure the coil reel is engaged with the spindle brake pin a
94. of the active parameter Parameter Ranges WELD MODE Adjustable per mode schedule PREFLOW 0 0 to 2 5 seconds 0 1 sec increments RUN IN Low Range 50 to 150 IPM 1 25 to 3 80 MPM High Range 75 to 150 IPM 2 00 to 3 80 MPM ARC CONTROL Trim 10 0 to 10 0 0 is nominal BURN BACK 0 0 to 0 25 sec 0 01 sec increments POSTFLOW 0 0 to 2 5 sec 0 1 sec increments CRATER ON or OFF Functions in 4 step trigger mode only Mode Schedule Table on the front of the option used by the operator to correlate the displayed mode number to an actual Power Source mode Due to the nature of the system the following feature is required for safety reasons upon entering any con stant current CC mode the right encoder labeled Volts Trim on the Display Control Panel acts as a soft contactor switch The encoder knob must be turned Clock Wise at least 45 to activate the output turning Counter Clock Wise 45 deactivates the out put This prevents the output from inadvertently becoming hot when scrolling through the weld modes The exception to this rule is when the weld mode is entered by a change in procedure using a memory panel such as the K1542 9 Memory Dual Procedure panel In this case the state of the contac tor is recalled as it was left when the procedure was exited In the CC modes the output current is set by the Amps control and the Volts Trim adjustment has no effect in this mode I
95. on Lincoln Guns Most competitive guns can be connected to the Power Feed by using one of the K1500 series adapter kits See Gun Adapters in ACCESSORIES section INSTALLATION A 12 GENERAL GUN CONNECTION GUIDELINES GUN CONNECTIONS GENERAL 4 roll feed plates are equipped with a brass connector bar at the gun end of the feed plate to allow a bolted brass to brass electrical connection to be made direct ly to either standard or Fast mate gun adapter bush ings Use a 1 4 inch allen key on the factory installed Socket head cap screw to insure that the connector bar is securely tightened to the adapter bushing The instructions supplied with the gun and K1500 series gun adapter should be followed when installing and configuring a gun What follows are some gener al guidelines that are not intended to cover all guns a Turn off input power at welding power source before installation or changing of gun b Check that the drive rolls and guide tubes are proper for the electrode size and type being used If not change them c Lay the cable out straight Insert the connector on the welding conductor cable into the brass conductor block on the front of the wire drive head Make sure it is all the way in and tighten the hand clamp Keep this connection clean and bright Connect the trigger control cable polarized plug into the mating 5 cavity receptacle on the front of the wire drive unit Note for Fast Mate and European conn
96. on conve nient to the user Doing so requires separating the Control Box from the Wire Drive mounting the Control Box in the desired location determining which recep tacle configuration is best for the application and installing the receptacle or receptacles for connecting control cables in the chosen configuration SEPARATING THE CONTROL BOX FROM THE WIRE DRIVE BENCH MODEL ONLY gt lt 1 Remove the bottom and center option panels from the front of the Control Box 2 Disconnect the Control Box to Wire Drive connec tion by disconnecting the 6 pin plug located in the hole which passes through the lower back of the Control Box to the Wire Drive 3 Loosen the four screws inside the Control Box located along the sides of the back of the Control Box two near the bottom and two near the middle 4 Push the Control Box upwards and pull away from the Wire Drive POWER FEED 10 LINCOLN A 3 INSTALLATION A 3 5 Remove plug button taped to inside of Control Box and insert it into hole on front panel of the Wire Drive MOUNTING THE CONTROL BOX BOOM OR SEPARATED BENCH MODELS The back plate of the Control Box has four keyhole slots for mounting See Figure A 2 for the size and location of these slots 10 screws are recommended for mounting 218 5 54mm Dia 4 Slots TOP 4 25 108mm M 6 88 175mm FIGURE A 2 DETERMINING RECEPTACLE CONFIGURATION The components in a Power Wave
97. ork 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 this installation Observe all additional Safety Guidelines detailed throughout this manual PRODUCT DESCRIPTION The Power Feed 10 is a high performance digitally controlled modular wire feeder Properly equipped it can support the GMAW GMAW P FCAW and SMAW processes The Power Feed wire feeders are designed to be a part of a modular multi process welding system The Power Feed 10 is a 4 driven roll feeder that oper ates on 40VDC input power The Power Feed wire feeders are designed to be used with Power Feed compatible power sources operating as a system Each component in the system has special circuitry to talk with the other system components so each component power source wire feeder electrical accessories knows what the other is doing at all times This shared information lays the groundwork for a system with superior welding perfor mance The Power Feed 10 is available configured in both boom and bench models In addition the Control Box and wire feed unit can also be purchased separately The bench model is designed so that it can eas
98. osition selects the GUN switch in which case the procedure is determined by the position of the switch located at the gun NOTE Due to the nature of fixed position switches this option does not allow the indication of a remotely selected procedure When in the gun mode there is no prevision to indicate at the Control Box which procedure has been remotely selected at the gun Installation is as follows 1 Turn off power 2 Remove the two screws from the front of the standard or option panel at the location you choose to install your new option middle of the Control Box cabinet Save the screws for re use Unplug the white electrical con nector Remove the chassis wire if equipped from the back of the standard or option panel Discard the old panel or save for future use 3 Tilt the new option panel away from the front opening of the Control Box cabinet and plug the white electrical connector into the proper connector on the right side of the main printed circuit board 10 pin until the connec tor latches into place Attach the chassis wire if equipped to the back of the new panel 4 Slide the new panel through the opening taking care not to damage the connections and the printed circuit board on the back 5 Align the screw holes Replace the two screws and tighten POWER FEED 10 LINCOLN C3 ACCESSORIES 3 K1542 6 M PANEL The M Panel provides a fixed large bat toggle switch selection of thre
99. ow and Crater default to zero or off Run in defaults to the minimum value or to the weld speed depending on the position of its associated dip switch See SETTING DIP SWITCHES in the INSTALLATION section Burn back defaults to the on board trimmer adjustment When used with the Dual Procedure or Memory options only the WFS Amps and Volts Trim settings are saved Selecting the Gouge mode immediately energizes the output terminals on the power source The output current is set by the Amps control The Volts Trim adjustment has no effect in this mode K1542 6 M Panel This panel has a three position toggle switch for selecting one of three weld modes CV MIG CV Flux Cored and CC Stick Gouge and a single knob for adjustment of Arc Control All other set up parame ters Preflow Postflow and Crater default to zero or off Run in defaults to the minimum value or to the weld speed depending on the position of its associat ed dip switch See SETTING DIP SWITCHES in the INSTALLATION section Burn back defaults to the on board trimmer adjustment When used with the Dual Procedure or Memory options only the WFS Amps and Volts Trim settings are saved Selecting the CC Stick Gouge mode immediately energizes the output terminals on the power source The output current is set by the Amps control The Volts Trim adjustment has no effect in this mode K1542 11 MX2 Panel This panel provides a selection of four weld modes CV MIG CV
100. 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 ww Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 4 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 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 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 2 d 5 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
101. 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 power source for pipe thawing LINCOLN CYLINDER may explode if damaged 7 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 cylin
102. 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 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
103. problem to a particular component See the following table for a complete listing and description of all status light conditions NOTE The green light ON and steady indicates a normal functioning system STATUS LIGHT STATES LED State Power Source LED LED on any other nodes components Wire Feeder Control Box Etc Off Power Source is not turned ON or is not func tioning correctly Green LED blink ing at a normal rate It should only blink for a few seconds while the system is mapping identifying compo nents If blinking continues every group may have a mapping error DIP switches may be set incorrectly Red LED blinking at a normal rate Indicates a recoverable communication fault The power source should automatically recover If it cannot recover the LED will be solid red Red Green LED blinking at a nor mal rate Indicates a recoverable hardware fault such as over temperature overload shutdown etc POWER FEED 10 LINCOLN The system component is not receiving input power or is faulty It should only blink for a few seconds until the system component node has been rec ognized If the blinking continues at least one node in the group has a mapping error DIP switches may be set incorrectly The node or nodes with mapping errors will be blinking red There may be too many components in the group All components in the group will be blinking green The power source bus may not b
104. r 7 from the group either by changing the group dip switch settings or physically disconnecting any objects over 7 in the group More than 1 object of the same Adjust the dip switch setting to make equipment type with the same group either the group or feed head and feed head unique for all objects 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 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 Source refer to wiring diagram Refer to Power source trouble shooting section for additional information If all these avenues fail replace CB mother PC 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 10 LINCOLN E 11 TROUBLESHOOTING E 11 Observe all Safety Guidelines detailed throughout this manual Note For any Err listed below write down the error n
105. rcuit board note connection point for re connection later Remove the option panel and set aside Remove the plastic plug black from the left hole in the bottom of the Control Box cabinet and store it in the bottom of the Control Box cabinet for future use should the Optional Output Connector be removed Place the Optional Output Connector Amphenol through the hole opened by the previous step place from the inside out Rotate the Optional Output Connector so it s aligning key is positioned to the front of the Control Box cabinet Fasten the Optional Output Connector to the bottom wall of the Control Box cabinet with the four screws pro vided Secure the choke large circular component of the Optional Output Connector by inserting it s leads into the white nylon clip located near the Optional Output Connector on the back wall of the Control Box cabinet Insert the choke leads only The Optional Output Connector has two internal connectors a four pin and a single lead connec tor Connect the four pin connector to the unused four pin connector on the main printed circuit board Connect the single lead connector to a similar connector found on a lead nearby that branches out of the Control Box wiring harness Re install the lower and middle option panels by reversing the removal process While re installing the option panels ensure clearance between Optional Output Connector components Control Box wirin
106. rd direction Holding the switch in either direction will result in the indicator advancing at a high rate of speed in that direction until the switch is released When the indicator reaches its upper or lower limit advancing ceases until the direction of the switch is changed Parameter Adjustment The value of the active parameter as defined by the parameter indicator is displayed on the parameter dis play The PARAMETER SET switch is a momentary large bat three position toggle switch that defaults to the center off position Moving the switch bat up advances the displayed value in the positive direction down advances it in the negative direction Holding the switch in either direction will result in the displayed value advancing at a high rate of speed in that direction until the switch is released When the indicator reaches its upper or lower limit advancing ceases until the direction of the switch is changed Crater fill operation is covered in the WIRE DRIVE OPERATION section Installation is as follows 1 Turn off power 2 Remove the two screws from the front of the stan dard or option panel at the location you choose to install your new option bottom of the Control Box cabinet Save the screws for re use Unplug the white electrical connector Remove the chassis wire if equipped from the back of the standard or option panel Discard the old panel or save for future use 3 Tilt the new option panel away from
107. rol Box Motherboard For software version S24456 1 Standard speed gearbox limits adjustable High speed gearbox limits adjustable 2 WFS Display inches minute WFS Display meters minute 3 Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing Left Display is actual weld current when weld current is flowing CC modes override this switch regardless of position Left Display is always preset weld cur rent when weld current is not flowing and actual weld current when weld current is flowing Run in Minimum Speed Available Run in weld WFS If any option containing a Run in setting is connected to the motherboard it automatically overrides this switch regardless of position Memory change with trigger disabled Memory change with trigger enabled 6 Acceleration MSB Sets acceleration rate for wire drive see below Acceleration Sets acceleration rate for wire drive see below EJ Acceleration LSB Sets acceleration rate for wire drive see below Note the factory shipped settings for the S1 switches are as follows PF 10 and Dual Domestic All switches OFF PF 10 and Dual European switches 1 amp 3 8 OFF 2 PF 11 Domestic switches 2 8 OFF 1 PF 11 European switches 3 8 OFF 1 2 ON S2 DIP Switch Bank on Control Box Motherboard For software version S24456 Network Group ID MSB Assigns Control Box to a specific group Off is factory setting
108. sert it into the hole in the front of the Feeder Head 8 Place the Optional Input Connector Amphenol through the hole opened by the previous step place from the inside out Rotate the Optional Input Connector so it s aligning key is positioned to the front of the Control Box cabinet Fasten the Optional Input Connector to the bottom wall of the Control Box cabinet with the four screws provided and connect the option s opposite end to the con nector referred to in step 4 9 Secure the choke large circular component of the Optional Input Connector by inserting it s leads into the white nylon clip located near the Optional Input Connector on the back wall of the Control Box cabinet Insert the choke leads only 10 Install an Optional Output Connector Lincoln stock 4 K1549 1 into the Control Box cabinet if not already present 11 Mount the Control Box cabinet to the work station fix ture at this time if desired The four holes in the back wall of the Control Box cabinet can be used for this purpose 12 Re install the lower and middle option panels by reversing the removal process While re installing the option panels ensure clearance between Optional Input Connector components Control Box wiring harness and option panel wiring har ness if any K162H WIRE SPINDLE ADAPTER Spindle for boom mounting Readi Reels and 2 51 mm 1 0 spools with up to 60 Ib 27 2 kg capacity User mounted to appropriately prepared
109. sible areas of switch Remove switch Check misadjustment have been checked continuity between switch pins and the problem persists Contact with switch open and closed If it your local Lincoln Authorized fails the continuity test repair Field Service Facility replace switch Faulty Local Dual procedure switch A 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 10 LINCOLN E 9 TROUBLESHOOTING E 9 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION 17 Dual Procedure is not function a Faulty local dual procedure ing when using the local dual procedure switch on Circuit Boards Status lights are solid green on Circuit Boards and Head boards 18 Wire feed speed is consistent and adjustable but operates at the wrong speed 19 Status LED not solid green switch or Circuit Boards mother board Disconnect harness plug from J5 of Circuit Board mother board Check that there is conti nuity between plug pins 1 and 7 local DPS is in position A but not when in gun or B Now check that there is continuity between plug pins 1and 8 when local DPS is in position B but not when in Gun or A If any of these continuity te
110. st from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and 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 FOR ENGINE 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 m MAGNE
111. struction 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 du corps PRECAUTIONS DE SURETE POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES A SOUDER A 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 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre
112. sts fail repair or replace switch or switch harness to correct the problem Otherwise replace CB mother board Dip switch on feed head board If all recommended possible areas of does not match gear ratio used at misadjustment have been checked gear box If using a high speed the problem persists Contact gear the feed head PC board dip your local Lincoln Authorized switch 8 must be set to 1 or ON Field Service Facility Feed head board is not properly reading DIP switch Replace feed head PC board a see LED Status Light Chart 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 10 LINCOLN E 10 TROUBLESHOOTING E 10 Observe all Safety Guidelines detailed throughout this manual 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 RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION Display shows any of the following More than 1 Circuit Board with the sure the group dip switch set same group number ting is unique for each Circuit Board Too many objects in group A given group can only support up to 7 objects Remove any objects ove
113. t WFS is adjustable on loose or faulty connections on Control Box motor tach See Wiring Diagram Wire feed motor turns and sole Power source is unable to noid operates but no arc voltage respond due to thermal or other is present Status light is solid type of shut down mode green on Control Box b Power source is defective See Power Source LED Status Light Chart If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10 LINCOLN E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION 10 Speed does not change when a Run in and weld speeds are set to weld current flows Status lights the same value are solid green Voltmeter and or ammeter do not function properly even though status lights are solid green Welding may vary from normal procedure Purge switch on feed head does a not activate solenoid but trigger closure in MIG or pulse modes does Cold feed switch does not acti vate the motor but trigger does in MIG or Pulse modes LEDs ar
114. t on the WFS knob This DIP switch setting is ignored by options which have the ability to adjust Run In MX2 and MSP2 panels See Setting DIP Switches in the Control Box section CONTROL BOX SETTING OPERATING LIMITS Upper and lower operating limits can be set for the WFS Amps setting and the Volts Trim setting Doing so requires knowledge of how to set the limits and access to the PC board in the Control Box There are two independent sets of limits Procedure A limits and Procedure B limits If a DP M door option is installed the A and B limits must be set independent ly If there is no DP M door option the Control Box defaults to Procedure A and only Procedure A limits can be set With system power on select the weld mode for which you want to set limits If a Dual Procedure option is installed select the procedure A Turn the system power off Remove the two screws holding the Control Display panel to the Control Box but do not unplug it Tilt the panel down to allow access to DIP switches S1 1 S2 6 and S2 7 See Setting DIP Switches in the Control Box section Do not allow the panel to hang by the wiring harness Determine if the Wire Drive is set up for low or high speed If low speed S1 1 should be off If high speed set 51 1 to on To adjust the lower limit set S2 6 to on Turn the power on and adjust the WFS Amps and Volts Trim knobs to the desired lower limits Note You will not be able to adjust the
115. the Select switch an up down center off momentary toggle switch Moving the switch bat up or down moves an LED in the corresponding direction Holding the switch in either direction will cause the indicator to move quickly in the corresponding direction until the switch is released or the upper or lower limit is reached The value of the active set up parameter is shown on the MSP2 panel digital display The value can be modi fied with the Set switch The Set switch is an up down center off momentary toggle switch Moving the switch bat up or down adjusts the displayed value in the cor responding direction Holding the switch in either direc tion will cause the display to move quickly in the corre sponding direction until the switch is released or the upper or lower parameter limit is reached To energize the output studs in either CC Stick mode the right Control Display panel knob labeled Volts Trim must be used The Volts Trim knob must be turned clockwise roughly a quarter revolution to energize the output studs The Volts trim display will indicate On when the studs are energized Similarly turning the knob a quarter turn counter clockwise de energizes the output studs If a CC Stick weld mode is entered through use of the Dual Procedure the studs will be in the same state as when they were last used If a CC Stick weld mode is entered through a Memory recall the studs will be de energized CONTROL BOX PANELS SE
116. the front open ing of the Control Box cabinet and plug the white electrical connector into the proper connector 12 pin on the right side of the main printed circuit board until the connector latches into place Attach the chassis wire if equipped to the back of the new panel 4 Slide the new panel through the opening taking care not to damage the connections and the printed cir cuit board on the back 5 Align the screw holes replace the two screws and tighten POWER FEED 10 LINCOLN 5 ACCESSORIES 5 1542 12 MSP2 PANEL AND 1542 10 MS STT PANEL LARGE PANEL The MSP2 or MS STT Panel provides a selection of numerous process specific and generic Power Source modes In addition it provides for the adjustment of the following parameters preflow run in arc control burnback postflow and spot time Only one parame ter as defined by the parameter indicator may be dis played and adjusted at a time The installation and operation of the MS STT panel is identical to the MSP2 panel The difference is that the MS STT selects STT procedures and is only function al when used with a Power Wave 455 STT Power Source Description Indicator Lights Extra bright red LED for viewing at almost any angle Always indicate the active parame ter being displayed Display Extra bright 3 1 2 digit 56 14 2 mm char acter height red LED display for viewing at almost any angle Displays the value or status
117. umber 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 RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION chonsan An attempt was made to reprogram for potential electrical HF a Circuit Board or feed head but the noise generators in the area Try program did not verify removing the noise source and pro gramming again If the Err 020 still occurs either replace the EEPROM chip s in the board being repro grammed 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 Power Source No heart beat response from an If this occurs while welding the sta object 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 recalled at power up was out of range Rotate Encoder Knob to reset Check all settings before proceeding to weld If this condition
118. wire feed unit should be mounted so that the drive rolls are in a vertical plane so that dirt will not collect in the drive roll area Position the mechanism so it will point down at about a 45 angle so the wire feed gun cable will not be bent sharply as it comes from the unit 281 7 14mm Dia 4 Holes 9 00 228 6mm 4 75 120 7mm FIGURE 1 ELECTRODE 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 the wire drive unit is kept at a minimum 5 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 MOUNTING CONTROL BOX AND RECEPTACLE CONFIGURATION The Control Box is designed for use in a variety of configurations A boom model feeder is shipped from the factory separated from the Wire Drive with the necessary receptacles installed In the case of a bench model feeder the Control Box can be removed from the Wire Drive and mounted in a locati
119. wire feeder is to order them with the K466 10 connector kit or to buy a completely assembled Magnum gun having the K466 10 connector such as the K471 21 22 and 23 dedicated Magnum 400 guns and the K497 20 and 21 dedicated Magnum 200 guns MAGNUM 550 GUNS The easiest and least expensive way to use the Magnum 550 guns with Power Feed 10 wire feeders is to order the gun with the K613 2 connector kit and install a K1500 3 gun connection kit to the wire feeder LINCOLN INNERSHIELD AND SUB ARC GUNS All of these guns can be connected to the Power Feed by using the K1500 1 Adapter Kit LINCOLN FUME EXTRACTION GUNS The K556 250XA and K566 400XA guns require that a K489 7 Fast Mate adapter kit be installed The K206 K289 and K309 require only the installa tion of a K1500 1 connector in the Power Feed wire feeder NON LINCOLN GUNS Most competitive guns can be connected to the Power Feed by using one of the K1500 series adapter kits ACCESSORIES C 10 GUN RECEIVER BUSHINGS AND ADAPTERS K489 7 DUAL SCHEDULE FAST MATE ADAPTER This adapter installs directly into the wire drive feed plate to provide for use of guns with Fast Mate or European style gun connections This K489 7 will handle both standard Fast Mate and Dual Schedule Fast Mate guns K1500 1 LINCOLN INNERSHIELD GUN STANDARD CONNECTION Use this kit to connect the following guns Guns hav ing a Lincoln standard Innershield gun connector
120. with Procedure A and Procedure B Set the Panel to A or B and recall a memory setting Make the slight proce dure adjustment it will be saved in A or B whichev er was selected when the adjustments were made The memory location will not have changed To recall a memory setting simply push that memory button That memory s contents will be immediately recalled to the Control box If the Memory Change with Trigger Pull DIP switch is on see SETTING DIP SWITCHES in the INSTALLATION section it is possible to recall a given memory by quickly pulling and releasing the gun trig ger before welding To switch to memory n simply pull and release the gun trigger n times without attempting to weld The trigger pulls and releases must be done quickly in rapid succession If too much time is allowed to pass the memory location will not change Note that whenever the trigger is pulled a welding sequence preflow run in etc begins so the electrode should not be allowed to contact the work piece CONTROL BOX PANELS LARGE OPTION PANELS A description of the set up controls Preflow Run In Arc Control Postflow and Crater and their maximum and minimum values is in CONTROL BOX PANELS SET UP CONTROLS DESCRIPTION in this section CV Gouge Panel Std The CV G Panel has a single toggle switch for select ing between two weld modes CV welding and arc gouging All other set up parameters Preflow Arc Control Postfl
121. ws the feeder to rotate on top of the power source The feeder can be easily separated from the swivel mount at any time This option is compatible with the K1556 1 Light Duty Caster Kit K1556 1 LIGHT DUTY CASTER KIT This option provides 4 casters and all required hard ware to mount it to the Power Feed 10 This option is compatible with the K1557 1 Swivel Mount ACCESSORIES C 12 K1574 1 SECURITY DOOR LARGE K1574 1 Security Door Installation into the Control Box Cabinet 1 Turn off power 2 Unlatch and swing open the small door Remove the two screws from the horizontal hinge rod Save the screws 3 While holding the door so it doesn t fall Slide the rod out sideways releasing the door 4 Position the new door between the panel holes and re install the rod so the screw holes can be accessed 5 Replace the two screws and tighten 6 Swing the door into the up position A lock may be installed through the side holes for security purposes K1555 1 INSULATED LIFT HOOK For applications where an insulated lift hook is required This kit provides an easily installed heavy duty insulated lift eye that mounts to the wire reel stand mast See the instructions provided with the kit for installation K1551 2 INCOMING BUSHING 4 Ball Roller Standard on codes 10600 and up This ball bearing equipped incoming bushing can be used in place of the standard incoming wire bushing when feeding solid steel or cored w
122. xi mate setting The optimum drive roll pressure varies with type of wire surface condition lubrication and hardness Too much pressure could cause birdnesting but too little pressure could cause wire feed slippage with load and or acceleration The optimum drive roll set ting can be determined as follows 1 Press end of gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds 49 If the wire birdnests jams or breaks at the drive roll the drive roll pressure is too great Back the pressure setting out turn run new wire through gun and repeat above steps 59 If the only result is drive roll slippage disengage the gun pull the gun cable forward about 6 150 mm There should be a slight waviness in the exposed wire If there is no waviness the pres sure is too low Increase the pressure setting turn reconnect the gun tighten locking clamp and repeat the above steps PROCEDURE FOR SETTING ANGLE OF FEEDPLATE 1 Loosen the clamping collar screw using a 3 16 Allen wrench The clamping collar screw is accessed from the bottom of the feedplate It is the screw which is perpendicular to the feeding direction 2 Rotate feedplate to the desired angle and tighten clamping collar screw GAS GUARD REGULATOR SETTING 1 With the gas supply shut off the Gas Guard regu lator flow adjusting Key should be set to maximum full clockwise whi

Lincoln Electric IM584-D User's Manual

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