Lincoln Electric K1780-1 User's Manual
Contents
1. O ec dn EH D 1 Drive Rolls and Guide Tubes D 1 Avoiding Wire Feeding Problems D 1 Periodice EE D 1 Procedure for Removing Feedplate from Wire D 1 Troubleshooting 1 1 0 Section E Safety PIecautlOns Maman entree M nie i ie 1 Troubleshooting Guide essen nnne E 2 thru E 4 REI Ir Section F Wiring Diagramm P F 1 Dimension ln E 2 Parts EEN P 381 Series vi 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS Power Feed 10 Robotic K1780 1 WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC TYPE LOW SPEED RATIO HIGH SPEED RATIO Wire Size Wire Size Speed Solid Cored Speed Solid Cored K1780 1 Power Feed 10 50 800 IPM 025 3 32 in 035 120 in 75 1200 IPM 025 1 16 in 035 5 64 in 1 27 20 3 m m 0 6 2 4 0 9 3 2 mm 2 08 30 5 m m 0 6 1 6mm 0 9 2 0 mm CONTROL BOX WIRE DRIVE AND COMPLETE UNITS SPEC TYPE INPUT POWER PHYSICAL SIZE TEMPERATURE RATING Dimensions Height Width Depth Weight Operating Storage K1780 1 Power 40 VDC 13 5 10 3 12 0 23 5 Lbs 20 to 40 40 to 40 Feed 10 340 mm 261 304 10 7 Kg Wire Feeder POWER FEED 10 R LINCOLN 52. eui j sjeued y euo uo y LL episu peised s e jenueu siy Aq 104 eq jou 104 SI SIUL 310 096 LIN 000c cl 3J19VIld3O38 1 lt YYYYYYYYYYY 8 30V3d31NI HYL DIAGRAMS dag VIN oooo 008 1 M 9018 N 934 43 MOVIE 9 DSNIGOO 40109 5913 334 STOSWAS 1V2IH L2313 HOLO3NNOO 30 34915 QV31WOd SY JDNANOAS ONINAGWAN ALIAVD 40 ACIS LN3NOdWOO WO SY ADNANOAS DNIH38WAN ALIAVD VN GION31OS CCS 9 31875 390310313 INdNI XO4HV19 HOLON 12 NAG Wd dit NOLDANNOD DNISN3S ADVLIOA 01 YAMOd 303 NVH9VIQ POWER FEED 10 R LINCOLN E POWER FEED 10 R DIMENSION PRINT DIAGRAMS 75 1 4 20 PLACES CIN k H POWER FEED 10 R LINCOLN L11579 NOTES POWER
3. 1 97 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn off the input power to the power source at the disconnect switch or fuse box before work ing on this equipment Turn off the input power to any other equipment connected to the weld ing system at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts Always connect the Power Wave grounding lug located inside the reconnect input access door to a proper safety Earth ground MOUNTING OF THE PF10 R Mount the wire drive unit by means of the 4 holes in the bottom of the wire drive base Note that the gear box assembly is electrically hot when welding Therefore make certain the gearbox does not come in contact with the structure on which the unit is mount ed The wire feed unit should be mounted so that the drive rolls are in a vertical plane to prevent the accu mulation of dirt in the drive roll area Do not bend the conduit more than 45 FIGURE A 1 22 DIA 2 Places 25 DIA 4 Places INSTALLATION A 2 ELECTRODE ROUTING The electrode supply may be either from reels Readi Reels spools or bulk packaged drums or reels Observe the following precautions Do not bend the conduit more than 45 and to use the minimum amount of conduit necessary for the wire reel to connect to the wire feeder The
4. Shielding Gas een ele WEE Control ee Control Cable eene e EE Control Cable 5 A 4 Wire Drive Gear Ratio High or Low Speed mme 4 Selecting the Gear Ratio Changing the Wire Drive Ratio Wire Feed Drive turre Procedure to Install Drive Rolls and Wire Guides A 6 Drive Roll Kit Installation KP1505 KP1507 e A 6 General Gun Connection Guidelines eem A 6 Gun Receiver Bushings and Adapters ssssssseeeeeneeeemns A 7 EE 7 Remote Sense Lead Specifications A 7 Installation of Field Installed Options ss A 7 Feeding Electrode and Brake Adjustment A 8 Drive Roll Pressure Settings A 8 is cose Rm Section B Safety Precautions E 1 DUV CYC D E en ae a 1 ER le e EE 1 Recommended ProCesses 1 gin e B 1 Recommended Equipment Interface B 1 ACCOSSONMICS A Section C Optional E IT ELE 1 Drive Roll and Guide Tube Kits C 1 DE Section D Safety Precautions AE D 1 Routine
5. 2 Remove the Phillips head screw retaining the pinion gear to be changed and remove the gear If the gear is not easily accessible or difficult to remove remove or adjust feed plate from the gearbox To remove feed plate Loosen the clamping collar screw using a 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 3 Loosen but do not remove the screw on the lower right face of the feed plate with a 3 16 Allen wrench 4 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 feeder If feed plate does not rotate to allow holes to line up further loosen the screw on right face of feed plate 5 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 6 Tighten the screw on lower right face of feed plate 7 R
6. Observe all additional Safety Guidelines detailed throughout this manual DRIVE ROLL KIT INSTALLATION KP1505 KP1507 WARNING 1 Turn OFF Welding Power Source 2 Pull open Pressure Door 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 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 GENERAL GUN CONNECTION GUIDELINES The instructions supplied with the gun and K1500 series gun adapter should be followed when installing and configuring a gun The following guidelines are general procedures only that are not intended to cover all guns 1 Check that the drive rolls and guide tubes are prop er for the electrode size and type being used 2 Lay the cable out straight Insert the connector on the welding conductor cable into the brass conduc tor block on t
7. RETURN MAIN MENU Power Feed 10 Robotic IM689 A K1780 1 May 2007 For use with machines having code numbers 10729 10801 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 E E EE LINCOLN Copyright 2007 Lincoln Global Inc World s Leader 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 A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS
8. ATTENTION German WARNUNG ATENCAO it ie BIR Chinese aadi oe lue chal ad TU Gal bacs ga d Jg Mall oe Quad Aie 404 pha NM 90 ail e AREY cuts UI ai tha Y e Aale veel Al dl LEIA COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SBM OBO X HD OMBRBEE lt K HA 94 EL TRHOKRERE HS ET EK E D LR RE EX BUR B 0 AIXIME SAAD HAY sei FAS PSP HHCH Saal veel d illai aul Jud AAL ell oig Gail ag ls Ca L LINCOLN B 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
9. FEED 10 LINCOLN 8 NOTES POWER FEED 10 LINCOLN 8 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la 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 e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra O EFOEREMR ELE LATE OMLMPT APSSAPREBS NTUSHILT FSU e E GUB MIU AER GH Oa CRM EER e Saiss Xe uc a Sal e sis HIE Weal gaali Y O aual ai ANI d ihs slt AA usa Jall JA dan wae 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 BEER MMIC LU THEW EKA e 2 07 Vi
10. GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and 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 the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable 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
11. a number of configurations They are designed to be used for GMAW GMAW P and FCAW for a variety of materials including mild steel stainless steel and cored wires PROCESS LIMITATIONS The feeders are capable of handling only some sub merged arc applications RECOMMENDED EQUIPMENT INTERFACE The Power Feed Robotic Feeders must be used with PowerWave 455 R PowerWave 655 R or other Robotic PowerWave source These are the only power source to supply the correct operating voltage 40 volts DC and communication method Arc Link digital communications required by the Power Feed 10 Robotic POWER FEED 10 R LINCOLN 5 1 OPTIONAL EQUIPMENT KP1505 Drive Roll and Wire Guide Kits KP1507 Drive Roll and Wire Guide Kits ACCESSORIES C1 PLATFORM COMMONALITIES The KP1507 series of drive roll kits contain a number of components in addition to the drive rolls to opti mize the wire feeder for aluminum feeding These components are specifically designed to protect the aluminum wire from abrasion and deformation there by avoiding many common aluminum feeding prob lems K1546 Conduit Power Feed 10 series Feedhead CGA gas connections Quick connect water connections Works with all PowerWave ArcLink systems It is not compatible with the PowerWave 350 450 or 500 or Linc net PowerWave 455 s OPERATIONAL FEATURES AND CONTROLS All procedure settings for the Power Feed 10 Robotic wire f
12. 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 POWER FEED 10 R LINCOLN 5 EM TROUBLESHOOTING E HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column pro
13. large reel supply the electrode to the PF 10 R with an elec trode conduit Minimize the number of bends in the conduit and the distance the electrode must travel 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 properly straightened it may not feed or may jam causing a bird nest 3 Insert the free end through the incoming guide tube 4 Activate the Cold Inch mode until the the drive rolls grab the electrode A WARNING When feeding with the 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 over tighten Drive Roll Pressure Setting The Power Feed 10 R drive roll pressures are factory pre set to about position 2 as shown on the pressure indicator on the front of the feed plate door This is an approximate setting The optimum drive roll pressure varies with type of wire surface condition lubrication and hardness Too much pressure could cause bird nesting but too little pressure could cause wire feed slippage with load and or acceleration The optimum drive
14. 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 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 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 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositi
15. operating with electrode polarity negative the switch 7 must be set to OFF Set the Negative Polarity switch on Wire Feed Head PC board as follows These instructions apply to the Power Wave 455 R and Power Wave 655 R Consult the manual for the power source if necessary WARNING 1 Turn off power to the power source at the dis connect switch 2 Remove the front cover from the power source 3 The wire feed head board is on the right side of the power source Locate the 8 position DIP switch and look for switch 7 of the DIP switch 4 Using a pencil or other small object slide the switch to the ON position for EE negative electrode polarity Conversely slide the switch to the OFF position for amp positive electrode polarity OZ 5 Replace the cover and screws The PC board will read the switch at power up automatically adjust ing all control parameters for the speed range selected SHIELDING GAS CONNECTION WARNING CYLINDER may explode if 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 cylin der Keep cylinder away from welding or 23 other live electrical circuits BUILDUP OF SHIELDING GAS may harm health or kill 8 Shut off shielding
16. roll set ting can be determined as follows 1 Press end of gun against a solid object that is elec trically isolated from the welder output and press the gun trigger for several seconds 2 If the wire bird nests jams or breaks at the drive roll the drive roll pressure is too great Back the pressure setting out 2 turns run new wire through gun and repeat above steps INSTALLATION A 8 3 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 pressure is too low Increase the pressure setting 3 turns recon nect the gun tighten locking clamp and repeat the above steps POWER FEED 10 R LINCOLN 5 1 OPERATION B 1 SAFETY INSTRUCTIONS Read and understand this entire section of operat ing instructions before operating the machine AA WARNING ELECTRIC can kill Unless using cold feed feature when feeding with gun trigger the electrode and drive mechanism are always electrically energized and could remain energized several sec onds after the welding ceases N Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be 23 dangerous AR Keep your head out of fumes B e Use ventilation or exhaust to
17. ATIO See Specification Section A 1 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 f 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 diameter gear 1 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 diameter gear Using the low speed ratio will provide the maximum available wire driving force The full range of wire feed speed listed in Section A 1 may not be useable for all welding programs Check your welding software to make sure the desired WFS falls within the welding software limits POWER FEED 10 R LINCOLN 5 5 INSTALLATION 5 CHANGING THE WIRE DRIVE RATIO WARNING ELECTRIC SHOCK can kill Turn off power to the power source at the disconnect switch Changing the ratio requires a gear change and a PC board switch change The Power Feed Wire Feeders are shipped with both high speed and a low speed gears As shipped from the factory the low speed high torque gear is installed on the feeder For iden tification purposes the low speed high torque gear has 20 teeth and is 1 1 inches in diameter The high Speed gear has 30 teeth and is 1 6 inches in diameter 1 Pull open the Pressure Door
18. S BET freA eis Ad d s Jo UN Aal AIX 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 protec o para a vista ouvido e corpo A HAUSHERMRELTTF EU OMAR HRSRSORENE ez 119 59 HEHA daig die Lilly lan alg t Bawa 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 e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur po
19. 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 A Cutting ANSI Standard 749 1 from the American Welding Society 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 A d T 1 h e scalding Ee the powered equipment E or pressure when the engine is 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 o 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 2 ELECTRIC AND MAGNETIC FIELDS may be dangerous 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 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 ign
20. Wire feeds properly Wire feed speed is consistent and adjustable but operates at the wrong speed 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 The wire drive motor may be overloaded Fault occurred Fault occurred Damaged leads to the motor tachometer Damaged tachometer Power source is unable to pro vide arc voltage because of ther mal shutdown or other failure Run in and weld speeds are set to the same value Fault occurred The work sense lead 21 or the electrode sense lead 67 may have intermittent or poor connec tions Improper power source selection on the control P C board Welding Program Error DIP switch is incorrectly set for the wrong wire drive or gear ratio 2 Fault occurred 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 R LINCOLN 5 T Jequunu epoo eu BAIN jueujeoe dai JO jueunuedeg eidel si
21. d 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 feed plate and drive rolls Clean them as necessary 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 section for roll chang ing instructions 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 bend the conduit more than 45 b Keep the minimum amount of conduit necessary for the wire reel to connect to the wire feeder 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
22. de 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 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se 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
23. e attach feed plate to wire feeder if removed in Step 2 8 Feed plate will be rotated out of position due to the gear change Adjust the angle of the feed plate per Item 2 Set the High Low switch code on Wire Drive PC board which is located on the Power Wave 455 R and Power Wave 655 R Consult the Instruction Manual for proper power source settings POWER FEED 10 R LINCOLN 5 6 INSTALLATION 6 WIRE 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 kill 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
24. eadjust if necessary 11 Improper liner tip or inner outer guides Replace if neces sary Incorrect wire drive or gear ratio selection on the control P C board Variable or hunting arc Wrong size worn and or melted contact tip Worn work cable or poor work connection Loose electrode or work cable connections CAUTION If for any reason you do not understand the test procedures 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 R LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual Variable or hunting arc Wrong size worn and or melted contact tip Worn work cable or poor work connection Loose electrode or work cable connections Wrong polarity Make sure electrode polarity is correct for process being used If all recommended possible areas of Gas nozzle extended beyond misadjustment have been checked gun tip or wire stickout too long and the problem persists Contact while welding your local Lincoln Authorized Field Service Facility Poor gas shielding on processes requiring gas Check gas flow and mixture Poor arc striking with sticking or 1 Improper procedures or tech blast offs weld porosity narrow niques See Gas Metal Arc and ropy looking bead or electr
25. eeder is through software control A DIP switch is used to indicate hardware settings TABLE 1 DRIVE ROLL AND GUIDE TUBE KITS Wire Size 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 0 045 1 2 mm 0 052 1 4 mm 1 16 1 6 5 64 2 0 3 32 2 4 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 0 068 1 7 mm 5 64 2 0 3 32 2 4 7 64 Lincore Hard Facing 2 8mm 7 64 2 8mm 120 3 Aluminum Electrode 0 035 0 9 mm 0 040 1 0 mm 3 64 1 2 mm 1 16 1 6 3 32 2 2 Series 1505 030 1505 030 1505 035 1505 0455 1505 0455 1505 0525 KP1505 1 16S KP1505 5 64 KP1505 3 32 KP1505 035C KP1505 035C KP1505 045C KP1505 045C KP1505 052C KP1505 1 16 KP1505 068 1505 5 64 1505 3 32 KP1505 7 64H KP1505 7 64 KP1505 120 KP1507 035A KP1507 040A KP1507 3 64A KP1507 1 16A KP1507 3 32 POWER FEED 10 LINCOLN 8 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground an
26. electrode is hot while welding and must be insulated from the boom conduit and wire payoff 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 ELECTRODE AND WORK CABLE CON NECTIONS Most welding applications run with the electrode being positive 4 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 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 unsatisfacto ry pulse welding performance Connect work lead of sufficient size and length per TABLE 1 between the proper output terminal on the power source and the work Be sure the connection to the work makes tight metal to metal electrical con tact To avoid interference problems with other equip ment and to achieve the best possible operation route all cables directly to the work or wire feeder Do not bundle the electrode and work leads tightly together Avoid excessive lengths and do not coil excess cable Use K1796 Coaxial welding cables whe
27. f 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 POWER FEED 10 R LINCOLN 8 for selecting QUALITY product by Lincoln Electric We want you nk You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any
28. gas supply when not in use SEE AMERICAN NATIONAL STANDARD 2 49 1 SAFETY IN WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY The 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 CONTROL CABLE CONTROL CABLE CONNECTIONS 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 component to another Components can be connected in any order as long as the proper input and output receptacles are present Connect the control cable from the Power Feed 10 Robotic Wire Drive to the output receptacle on the PowerWave NOTE The maximum cable length between the Power Feed 10 Robotic and the power source is 100 feet 33 m POWER FEED 10 R LINCOLN 8 4 CONTROL CABLE SPECIFICATIONS is recommended that genuine Lincoln control cables be used at all times Lincoln cables are specifically designed for the communication and power needs of the Power Wave Power Feed system The use of non standard cables especially in lengt
29. he conduit remove it from the feeder end of the conduit by unscrewing it Insert the conduit into the K1546 1 or K1546 2 secure the conduit by fastening it the adapter with the supplied knob screw For E Beam 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 Insert the conduit into the K1546 2 secure the conduit by fastening it the adapter with the supplied knob screw REMOTE SENSE LEAD SPECIFICATIONS The Power Feed10 R should always be operated with the voltage sense lead 67 attached to the feed plate INSTALLATION OF FIELD INSTALLED OPTIONS Water Flow Sensor Water cooled guns can be damaged very quickly if they are used even momentarily without water flowing Recommend practice is to install a water flow sensor on the water return line of the torch When fully inte grated into the welding system the sensor will prevent welding if no water flow is present Gas Guard Regulator The Gas Guard regulator is available as an optional accessory K659 1 for Power Feed Robotic wire drive unit Install the 5 8 18 male outlet of the regulator to the proper 5 8 18 female gas inlet on the back panel of the wire drive Secure fitting with flow adjuster key at top POWER FEED 10 R LINCOLN 8 8 Feeding Electrode and Brake Adjustment 1 Turn the Reel or spool until the free end of the elec is accessible using drum or
30. he 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 Note For Fast Mate and European connector 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 the large nut on gun clockwise 3 For GMA Gun Cables with separate gas fittings connect the gas hose from the wire drive unit to the gun cable barbed fitting See ACCESSORIES SECTION Table C 1 page C 1 POWER FEED 10 R LINCOLN A 7 INSTALLATION A 7 GUN RECEIVER BUSHINGS AND ADAPTERS The Power Feed wire feeders are equipped with facto ry installed K1500 2 gun connection kits These kits are for guns having a Tweco 2 4 type connector The Power Feed 10 R has been designed to make connecting a variety of guns easy and inexpensive with the K1500 series of gun connection kits Non Lincoln Guns Most competitive guns can be connected to the Power Feed 10 R by using one of the K1500 series adapter kits See Gun Adapters in ACCESSORIES section 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 connec tion Use this kit to connect the following gu
31. hs greater than 25 feet can lead to communication problems system shutdowns poor motor acceleration poor arc starting and low wire driving force wire feeding problems Lincoln control cables are copper 22 conductor cable in a SO type rubber jacket TABLE 2 CONNECTOR WIRING PinlLead Function 15 Tach voltage Tach common Tach 1A differential signal Tach 1B differential signal Tach 2A differential signal Tach 2B differential signal Single Tach Input Reserved for future use Voltage sense lead Motor Motor Reserved for future use Reserved for future use 40vdc for solenoid solenoid input Reserved for future use Reserved for future use Shield ground to case Reserved for future use Reserved for future use Reserved for future use Reserved for future use A B D L M N P R S T U V W X AVAILABLE CABLE ASSEMBLIES K1795 Control cable only Available in lengths of 25 50 and 100 INSTALLATION 4 WIRE DRIVE GEAR RATIO HIGH OR LOW SPEED The speed range capability and drive torque of the Power Feed wire drives can be easily and quickly changed by changing the external drive gear The Power Feed Wire Feeders are shipped with both high speed and a low speed gears 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 be made SELECTING THE PROPER GEAR R
32. ight side ai Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 POWER FEED 10 R LINCOLN 8 ELECTRIC SHOCK kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel
33. ions Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations POWER FEED 10 R LINCOLN 8 SAFETY PR CAUTIONS S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vi
34. iting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 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 In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the 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 r
35. ns Guns hav ing a Lincoln standard innershield gun connector Magnum 200 300 400 with K466 1 connector kit and Magnum 550 guns with the K613 1 gun connection kit K1500 2 Tweco 2 4 type connection The K1500 2 gun adapter comes factory installed on the Power Feed 10 R wire feeder Use this adapter for guns that have a Tweco 72 24 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 K1500 5 Oxo connection For any gun having an Oxo style threaded connector Install gun adapter per the instructions shipped with it CONDUIT ADAPTERS The K1546 1 and K1546 2 Adapter for use with Lincoln Magnum conduit K515 or 565 and E Beam conduit The K1546 1 is to be used for wire sizes 023 1 16 K1546 2 is to be used for wire sizes 1 16 120 For Magnum conduit Install the K1546 1 or K1546 2 adapter at the incom ing 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 t
36. ode 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 rubber seal for any sign of dete rioration or damage Be sure set screw in connector block is in place and tightened against the liner bushing 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 R LINCOLN 5 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION Tip seizes in diffuser 1 Tip overheating due to pro longed or excessive high current Motor does not turn when trigger is pulled The drive motor does not turn although arc voltage is present and the gas solenoid is on No control of wire feed speed motor Gas solenoid operates properly and arc voltage is present Wire feed speed can be set through ArcLink but WFS is erratic Wire feed motor turns and gas sole noid operates but no arc voltage is present Speed does not change when weld current flows Erratic arc length especially with a pulse or STT program Welding may or may not vary from normal procedure
37. only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 1 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 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 recommendat
38. remove fumes from breathing zone WELDING SPARKS can cause fire or explosion EN Keep flammable material away Do not weld on containers that have held combustibles Z ARC RAYS can burn L Wear eye ear and body protection Observe additional Safety Guidelines detailed in the beginning of this manual DUTY CYCLE The Power Feed wire feeders are capable of welding at a 10096 duty cycle continuous welding The power source will be the limiting factor in determining system duty cycle capability GENERAL DESCRIPTION The Power Feed 10 Robotic is a high performance digitally controlled modular wire feeder Properly equipped it can support the GMAW GMAW P and FCAW processes The Power Feed wire feeders are designed to be a part of a modular multi process welding system The Power Feed 10 Robotic is a 4 driven roll feeder that operates on 40VDC input power The Power Feed Robotic wire feeders are designed to be used with Robotic PowerWaves Close integration of the feeder power source and customer s equip ment creates the foundation for a system with superior welding performance The Power Feed 10 Robotic is intended for automatic applications It specifically designed to mount to a robot arm or to use in hard automation applications Operation for the Power Feed 10 Robotic is with a Power Feed compatible robotic power source RECOMMENDED PROCESSES The Power Feed Wire Feeders can be set up in
39. responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is e
40. rever possible Minimum work and electrode cables sizes are as follows TABLE 1 MINIMUM COPPER WORK CABLE SIZE AWG Current 60 Duty Cycle Up To 100 Ft Length 30 m 400 Amps 2 0 67 mm2 500 Amps 3 0 85 mm2 600 Amps 3 0 85 mm2 POWER FEED 10 R LINCOLN 8 3 INSTALLATION 3 When using inverter type power source Use the largest welding electrode and work 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 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 wire drive feed plate using the stud lockwasher and nut provided on the wire drive feed plate The elec trode cable lug must be against the feed plate Be sure the connection to the feed plate makes tight metal to metal electrical contact The electrode cable should be sized according to the specifications given in the work cable connections section NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required such as in some Innershield applications reverse the output connections at the power source electrode cable to the negative stud and work cable to the positive stud When
41. specially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE CONTENTS Page INSTANATION EE Section A Technical Specifications A 1 Safety TEE 2 Mounting the Wire Drive Unit sisi A 2 Electrode ROUTING ce arrete a sen ACEN A 2 Electrode and Work Cable Connections een eee A 2 Negative Electrode Polarity
42. t cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and folllow 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 CYLINDER may explode if damaged 7 Use
43. ur ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria E1 APSMERTLIICLT 9 gt za 24752 e SUAS MAS AH PARAH 37 amp MBH 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 opere com as tampas removidas Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e X7TTLA 9 UACRU EFBRAL FE DF gt TKR e HE BIS ER 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 11 L EUITTF amp L KEE KEN e 800 Yel Me z Spanish AVISO DE PRECAUCION French
44. vides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 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 R LINCOLN 5 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual Rough wire feeding or wire not 1 Gun cable kinked and or twist feeding but drive rolls are turning ed Wire jammed in gun and cable Check for mechanical restric tions in feeding path Check for current position of drive rolls relative to split wire guide groove Drive rolls may not be seated properly Gun cable dirty clean if neces sary Worn drive roll Electrode rusty and or dirty Cable frayed or poor sol der joint at work or electrode lug If all recommended possible areas of misadjustment have been Worn nozzle or cable liner checked and the problem persists Replace if necessary Contact your local Lincoln Authorized Field Service Facility Partially flashed or melted con tact tip Replace if necessary 10 Incorrect drive roll pressure R
45. 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 POWER FEED 10 R LINCOLN 5 7 WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will no
46. 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 L RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 4 AUG 06 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 3 FUMES AND
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