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Lincoln Electric IM613-B User's Manual

1. D 1 vii TABLE OF CONTENTS Page Troubleshooting isir ii Section E Safety Pr cautions se MIT doi E 1 Troubleshooting GUIAS uo Air I Re mn Re ade ua tec al dees E 2 A ss nn Sasha aa u te te uns Section F Wiring Power Feed 11 Wire Feeder a F 1 Wiring Power Feed 11 Control Box F 2 Dime nsion Print 48 08e ad qe F 3 Parts E e u n u a Sus riores e cin P315 Series A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS Power Feed 11 COMPLETE UNITS SPEC TYPE LOW SPEED RATIO HIGH SPEED RATIO Wire Size Wire Size Speed Solid Cored Speed Solid Cored K1635 1 Power Feed 11 50 625 IPM 025 1 16 in 030 5 64 in 75 1100 IPM 025 045 in 030 045 in Cabinet 1 27 15 9 m m 0 6 1 6 mm 0 8 2 0 mm 2 03 27 9 m m 0 6 1 2 mm 0 8 1 2 mm Wire Feeder World Model K1636 1 Power Feed 11 50 625 IPM 025 1 16 in 035 5 64 in 75 1100 IPM 025 045 in 035 045 in Cabinet 1 27 15 9 m m 0 6 1 6 mm 0 9 2 0 mm 2 03 27 9 m m 0 6 1 2 mm 0 9 1 2 mm Wire Feeder European Model COMPLETE UNITS SPEC TYPE INPUT POWER PHYSICAL SIZE TEMPERATURE RATING Dimensions Height Width Depth Weight Operating Storage K1635 1 Power 40 VDC 20 0 9 0 28 7 61 Lbs Feed 11 508 mm 230 mm 729mm 27 7 Kg World Model 40 C 40 C to to K1636 1 Power 40 VDC 20 0 9 0 28
2. A 11 OPTIONAL FEATURES INSTALLATION A number of Optional Features are available for use with Power Feed 11 Some Installation informa tion is provided in this section REFER TO THE INSTRUCTIONS 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 11 Control Box is designed to accept two con trol panels and one door option Panels can be mounted in one of two positions Upper and lower Each Control Box is shipped with a Control Display CD panel installed in the upper position and a CV Gouge CV G panel in the lower position The CD panel must be installed in every Control Box The remaining panel can be one of the following CV G MX2 or MSP2 Note The CD panel must be installed in the upper position its harness is not long enough to allow installation in the lower position Similarly option panels must be installed in the lower position INSTALLATION A 11 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 Contro
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4. RETURN TO MAIN MENU Power Feed 1 1 SemiAutomatic IM613 B Cabinet Wire Feeder October 2000 For use with Power Feed 11 K1635 1 World Model Code 10529 10777 Power Feed 11 K1636 1 European Model Code 10531 10778 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 Date of Purchase Serial Number Code Number Model Where Purchased OPERATOR S MANUAL e A ms ufactured Under a gram Certified by ABS Quality Evaluations Inc to ISO 9002 Requirements CERTIFICATE NUMBER 30273 LINCOLN Copyright 2000 Lincoln Global Inc e World s Leader in Welding and Cutting Products e 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 i SAFETY l A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cau
5. 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 Si s Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety LZ se minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around you
6. e solez 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 N o toque partes el tricas e elec trodos com a pele ou roupa molha da O Isole se da peca e terra ORBPOBARA RABE ELE het EE LATE OHLMPT APYORAPHRBS NTWSHRELTFSU e RREAN DEBREREAR SR MERGE TA e small S458 N2 Jy Ez s qa Sal HAR e 2x9 HIE Weal HAR A A gone ll el all Qual YO Hull e ag SONT gh la S ell A dal Jai P dua e die aa e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e 24 pd U DORMTORRIER HN U THEN EA ep ES ML 1F32 PF o LS Y Aal He Ad d s s S dall pis Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo e B HRUSBCRBRELTE iD RR HRARGHRBAR ex 19 Sal HSE HSSHAR dis due de Lily lan Gl ysl o A ag 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
7. 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 understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility symptom 44 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 Observe all additional Safety Guidelines detailed throughout this manual 44 CAUTION If for any reason you do not understand the test procedures or are unable to perfo
8. 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 POWER FEED 11 LINCOLN B 3 OPERATION B 3 K1542 12 MSP2 Panel Optional 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 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
9. Wire Drive and on the welding pro grams in the Power Wave power source The voltage and current are similarly limited by programs in the Power Wave Control Box Panels Lower Panels A description of the set up controls Preflow Run In Arc Control Postflow and Crater and their maximum and mini mum values is in Control Box Panels Set Up Controls Description in this section K1542 4 CV Gouge Panel Std The CV G Panel has a single toggle switch for selecting between two weld modes CV welding and arc gouging All other set up parameters Preflow Arc Control Postflow and Crater default to zero or off Run in defaults to the mini mum value or to the weld speed depending on the position of its associated dip switch See Setting DIP Switches in the Control Box 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 cur rent is set by the Amps control The Volts Trim adjust ment has no effect in this mode K1542 11 MX2 Panel Optional This panel provides a selection of four weld modes CV MIG CV 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 para meters Preflow Run In Arc Control Burnback Postflow and Cra
10. 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 If 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 setting 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
11. 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 Off 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 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 optio
12. 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 LINCOLN CYLINDER may explode SC s if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely
13. 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 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 11 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 in this section WIRE FEED OVERLOAD PROTECTION T
14. chained to an undercarriage or fixed support Cylinders should be located e Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in 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 Mar 95 i SAFETY i PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dan
15. 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 Acceleration MSB Sets acceleration rate for wire drive see below Acceleration Sets acceleration rate for wire drive see below Wes Acceleration LSB Sets acceleration rate for wire drive see below Acceleration 2 Acceleration 3 Acceleration 4 Acceleration 5 fast factory setting Note the factory shipped settings for Switch S1 are as follows PF 11 European Switches 1 2 ON Switches 3 8 OFF PF 11 World Switch 1 ON Switches 2 8 OFF POWER FEED 11 LINCOLN A 7 INSTALLATION A 7 S2 DIP Switch Bank on Control Box Motherboard For software version S24456 1 Network Group ID MSB Assigns Control Box to a specific group Off is factory setting Network Group ID LSB Assigns Control Box to a specific group Off is factory setting 4 Step Domestic Configuration 4 Step European Configuration Es ES Must be off for normal operation Adjust lower limits Must be off for normal operation Adjust upper limits Must be on
16. 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 grease Do not use graphite grease Gun and Cable Maintenance See appropriate Operator s Manual Procedure for Removing Feedplate from Wire Feeder 1 Using a 3 16 Hex Key Wrench remove the two screws that secure the Feedplate to the Interface Plate These screws are located just below and to the right and left of the lower drive gears 2 Disconnect the Electrode Lead from the Feedplate 3 Swing the rear of the Feedplate out towards the front of the machine which will allow it to be pulled back and out of the machine 4 Remove the gas hose and disconnect the gun leads POWER FEED 11 LINCOLN E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE 44 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
17. for technical troubleshooting assistance before you proceed POWER FEED 11 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 MAN More than 1 CB with the same group Make sure the group dip switch set ting is unique for each CB Too many objects in group A given group can only support up to 7 objects Remove any objects over 7 from the group either by changing the group dip switch 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 8 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 Check to see if the status light is not mand from the power source solid green on the power source refer to status light states in OPER ATION s
18. 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 5 e Also see item 1 b Mar 95 LINCOLN SAFETY 3 7 WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums 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
19. little or no overrun when wire feeding is stopped Do not overtighten DRIVE ROLL PRESSURE SETTING The Power Feed 11 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 approxi 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 OPERATION D B 8 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 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 O TZ 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 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 which is rated to be 60 SCFH 28 l min 2
20. low speed ratio use the following guidelines When operating at wire feed speeds above 625 IPM 15 9 m m you must have the high speed gear large 30 tooth 1 6 inch diameter gear installed When operating at wire feed speeds below 625 IPM 15 9 m m you must have the low speed gear small 17 tooth 95 inch diameter gear installed for all wire sizes because using the low speed ratio pro vides the maximum available wire feeding force Note If you are feeding only 045 1 2 mm diame ter and smaller wires you may at your option use the factory installed high speed ratio CHANGING THE WIRE DRIVE RATIO Changing the ratio requires a gear change and a PC board switch change The Power Feed 11 is shipped with both a high speed and a low speed gear As shipped from the factory the high speed low torque gear is installed on the feeder For identification pur poses the low speed high torque gear has 17 teeth and is 95 inches in diameter The high speed gear has 30 teeth and is 1 6 inches in diameter See Figure A 2 PHILLIPS HEAD SCREW FIGURE A 2 CHANGING WIRE DRIVE RATIO DRIVE GEAR POWER FEED 11 LINCOLN A 5 INSTALLATION A 5 RATIO CHANGE PROCEDURE 1 Power down the Power Feed by turning OFF its companion PowerWave power source For maxi mum safety disconnect the control cable from the Power Feed 2 Pull open the Wire Feeder s Compartment Door 3 Remove the Feedplate
21. 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 11 LINCOLN B 6 OPERATION B 6 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 near the gun connector This switch has no effect in CC modes of operation such as stick welding Europe and World 2 Step Logic 1 Closing the gun trigger initiates the welding sequence preflow run in etc 2 Opening the gun trigger ends the welding sequence burnback postflow etc World 4 Step Logic With Crater Fill OFF 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 allows the weld to contin ue 4 Opening the trigger again ends the welding sequence burnback postflow etc 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 t
22. per the following a Disconnected the Electrode from the Feedplate b Pull open the Wire Drive Pressure Door c Using a 3 16 Hex Key Wrench remove the two screws that secure the Feedplate to the Interface Plate These screws are located just below and to the right and just below and to left of the lower drive gears d Swing the rear of the Feedplate out towards the front of the machine which will allow it to be pulled back and out of the machine Note The shielding gas hose and gun leads are still attached to the Feedplate This is OK provided that the Feedplate is setting on a suitable surface such that no excess tension is being place on the gas hose and gun leads If necessary remove the gas hose and disconnect the leads 4 Remove the pinion gear as follows a Using a phillips head screwdriver remove the screw that secures the gear to the output shaft of the gearbox and remove the gear Lightly cover the output shaft with engine oil or equivalent Install appropriate size gear small gear for low speed and a large gear for high speed onto output shaft and secure with flat washer lock washer and Phillips head screw which were previously removed e wm Note Be sure that the woodruff key remains secured to the output shaft during the gear change 5 Position the Motor Gearbox as follows a There are 4 screws that secure the Motor Gearbox to the Interface Plate Using a 3 16 Hex Key Wrench remove the 2 upper scre
23. proceed POWER FEED 11 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION 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 local 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 Ja 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 A CAUTION If for any reason you do not understand the test proce
24. technical troubleshooting assistance before you proceed POWER FEED 11 LINCOLN E 8 TROUBLESHOOTING E 8 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION 15 Display s are blank Power source is OFF Feeder supply or fuse circuit at power source is blown or tripped or defective harness or cabling c Display or CB 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 CB to gun Refer to solid green on CB and head operating instructions boards Faulty remote dual procedure If all recommended possible 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 or 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 11 LINCOLN E 9 TROUBLESHOOTING E 9 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMM
25. 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 modified 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 corresponding direction Holding the switch in either direction will cause the display to move quickly in the corresponding 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 K1640 1 Dual Procedure Memory Door Panel Optional 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
26. 311938 Z 699 GION310S SVO V0rs Ko V rs voor VL S GuYVOd O d IONLNOD NO OO O d 10313S ASNAS J YLIOA NO air DUT XL ir EP Ir 9 Ei RE zi v rr LL x vr ARCO ve 000 000 000000 000000 00000 00000 ooo 000 00 00 L F 1 z Sech e YOLO3NNO9 dO 3018 qv31 WO q3N3IA SV SONSNDAS NIYIANWNN ALIAVO 4303733 341M LE 03331 YIMOd NVWIIVIO DNIJIM L eb SNIGOO 40109 AVI LESLA 434 SIOEWAS 1V91419373 NOILOANNOO SISSVHO HO LIAAS dO ACIS NOILOANNOO WOU NMOHS SIHILIMS 319901 ON 134908 031 dO dV31 SEW HLIM SN NY 300H_LVO SN31 q31 JO 3903 LV14 IHL 1S3YV3N Nid V N SALON POWER FEED 11 LINCOLN N u quunu po2o 1u uudinb y anc Ju uu oe d i e 104 zju awped q 3211435 eu 0 AUM 3 Q163 1 S weep au y sjaued aunso us y Jo uo uo aulyoeu y LL apisul paysed si apo Jejn gt nued e 104 Weep 2u172ede ay 1 penueu siy Aq paano saulyoeu IS JOJ a3e1m5e aq jou Aew y AJUO a3ualajal 104 SI Weep SIUL 31LON EESOTT XO IOULNOD HLIHM M NOIL4O NOILOHNNOD SISSWHO Owe ee Tanva uooq TANYA WOLLOG TANYA OL DNIGOD HOOD gea LESTE uma SIOMWAS IVOIULOATE LHNISVO aasad OL NMoq AQIS INANO4NOD quvog Dd JO HDAH NON qHMHIA SV ADNAIN AS DONIUHENNN ALIAVO 4 r 4 N
27. 7 61 Lbs 20 C 40 C Feed 11 508 mm 230 mm 729mm 27 7 Kg European Model The PF 11 is environmentally rated IP21S per IEC60529 POWER FEED 11 LINCOLN A 2 INSTALLATION A 2 SAFETY PRECAUTION e ELECTRIC SHOCK can kill Only qualified personnel should per form this installation e 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 e Always connect the Power Wave grounding lug located inside the reconnect input access door to a proper safety Earth ground WIRE FEEDER TO POWER SOURCE CONFIGURATIONS The Wire Feeder is equipped to operate in the vertical or horizontal position It is shipped ready for use in the in the vertical position MOUNTING ON TOP OF THE POWER SOURCE The Wire Feeder is shipped with the vertical mounting bracket installed on the bottom of the Feeder The Feeder must be placed on top right side of the Power Source such that the bolt on the mounting bracket goes thru the hole in the Power Source s Lift Bail and the front hole on the right front foot of the mounting bracket is placed over the weld stud on the roof of the Power Source Use the Wing Nut washer assembly provided to secure the
28. 9 Install Outer Wire Guide by sliding over locating pins and tightening in place 10 Engage upper drive rolls if they are in the open position and close Pressure Door NOTE To set drive roll pressure see DRIVE ROLL PRESSURE SETTING in the OPERATION section GUN AND CABLE ASSEMBLIES The Power Feed 11 wire feeder is equipped with a Fast Mate Gun Adapter that provides for the use of guns with Fast Mate or European style gun connec tions and will handle both standard Fast Mate and Dual Schedule Fast Mate guns The Fast Mate Gun Adapter requires the use of wire guide tubes The Power Feed 11 is supplied with 4 wire guide tubes See FAST MATE GUN ADAPTER GUIDE TUBES and DRIVE ROLL KIT AND GUIDE TUBE INSTALLATION sections for prop er selection and installation of Fast Mate Gun Adapter wire guide tubes MAGNUM GUNS Magnum Fast Mate air cooled and water cooled gun and cable assemblies are available to allow weld ing with solid and cored wire electrodes See the appropriate Magnum Literature for descriptions of the 200 to 400 ampere air cooled gun and cables that are available as well as the Magnum 450 ampere water cooled gun and cable Magnum X Tractor gun and cable assemblies provide fume extraction capability for welding with solid and cored wire electrodes See the appropriate Magnum Literature for descriptions of the 250 to 400 ampere air cooled gun and cable assemblies that are avail able No
29. 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 11 LINCOLN B 9 OPERATION B 9 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 4 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 6 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 7 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 to use correct eye LZ head and
30. Drive Compartment Door 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 3 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 to de reel from the bottom of the coil 4 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining ring groove on the spin dle POWER FEED 11 LINCOLN B 8 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 TZ Insert the free end through the incoming guide tube 4 Press the Cold Inch key or the Cold Feed Mode gun trigger and push the electrode into the drive roll 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
31. ENDED SYMPTOMS POSSIBLE SAUSE COURSE OF ACTION 17 Dual Procedure is not function ing when using the local dual procedure switch on CB Status lights are solid green on CB and Head boards 18 Wire feed speed is consistent and adjustable but operates at the wrong speed 19 Status LED not solid green a Faulty local dual procedure switch or CB mother board Disconnect harness plug from J5 of CB mother board Check that there is continuity between plug pins 1 and 7 local DPS is in posi tion A but not when in gun or B Now check that there is con tinuity between plug pins 1and 8 when local DPS is in position B but not when in Gun or A If any of these continuity tests fail repair or replace switch or switch harness to correct the problem Otherwise replace CB mother board Dip switch on feed head board does not match gear ratio used at lf all recommended possible areas of gear box If using a high speed misadjustment have been checked gear the feed head PC board dip Jand the problem persists Contact switch 8 must be set to 1 or ONT your local Lincoln Authorized Field Service Facility Feed head board is not properly reading DIP switch Replace feed head PC board see LED Status Light Chart 44 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
32. Feeder to the Power Source Note The Wire Feeder can also be mounted horizon tally See ACCESSORIES section for information on the Optional Horizontal Mounting Bracket HANGING The Wire Feeder is equipped with 2 insulated Lifting Eyes for hanging the Feeder It is recommended that the Lifting Eyes always be used when hanging the Feeder The Lifting Handles should be used for short term carrying of the Feeder Note A longer or additional Control Cable may be required when hanging the Feeder See ACCES SORIES section for information on optional Control Cables ON THE FLOOR The Wire Feeder is equipped with aluminum skids which protect the enclosure when the Feeder is placed on the floor in either the horizontal or vertical position CONTROL BOX ORIENTATION The Control Box is designed to be easily rotated to accommodate horizontal or vertical positions The pro cedure to change the Control Box Orientation is as fol lows 1 Open the Wire Drive compartment door 2 Locate the Retaining Collar just above the Wire Drive unit and depress the Release Bar and remove the Retaining Collar from the Control Box mounting shaft 3 Pull the Control Box out just enough to allow the Control Box to be rotated to the desired position and then re install Be sure no leads are pinched Note For the Horizontal position the right side of the Control Box must be next to the front panel components 4 Re install the Retaining Coll
33. 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 LINCOLN e World s Leader in Welding and Cutting Products e 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
34. OILWWYOANI TVNOILIQqQV YOA HVUDVIA DNIYIM S NOILdO per s gt F AHL SHS SHAUIM NMOHS HHL A0 TIY HAVH LON AWW GHTIWLSNI NOILdO HHL E P al qrososr IEADOS GHT 40 gen POT MOWIG HLIM SN ITY AQOHLY SNIT GIT JO S903 LWId HHL LSHUVEN NIA 0 Lol 1 kHOLDINNOD 40 ACIS VAT WOYA AHMAIA SY HONANOES ONIUAGWAN XLIAVO 4 Ka Er qavog Od 40 ACIS LNANO4WOD MOYA CAMAIA SV HONANOES ONIUHENAN XLIAVO ERD NOILdO H Weg GE 0008 Pe TaNva Les ge ge HHMOT ees ess lt W2TS gt l Mie DIAGRAMS SSS te WEN qaq SALVIS qwuvog o a M 9ue 099 YECODNE res lt pl a He CES a e ess ote e e e e 1 ot 005 DD ets n gt gt gt o gt ATHLON NOILdO EECHER ZO TOALNOD TT AH444 YHMOd NV4DvId ONTAIM F 2 POWER FEED 11 LINCOLN F 3 3N 4 ve8011 LHHOVY4 NO SATOH ONIINNON 69 82 raar aert LEADVUE NO SATOH NILNNON 00 TZ DIAGRAMS 1 y 06 ke OTE DEN tt F 3 6S 6T POWER FEED 11 LINCOLN NOTES POWER FEED 11 LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is c
35. Observe all additional Safety Guidelines detailed throughout this manual DRIVE ROLL KIT AND GUIDE TUBE INSTALLATION 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 Feed plate 4 Remove drive rolls if any are installed by pulling straight off shaft Remove inner guide Note Not all Drive Roll and Wire Guide changes require changing the Gun Adapter Guide Tubes See FAST MATETM GUN ADAPTER GUIDE TUBES in this section for the proper size guide tube required for the wire size to be used If a guide tube change is NOT required skip Steps 5 amp 6 And go to Step 7 5 Loosen the small Knurled Knob on the Feedhead This the Knurled Knob that is closest to the Gun Adapter and is used to secure the wire guide tube into the Gun Adapter 6 Insert the new wire guide tube either end tube is symmetric into the incoming end of the Gun Adapter This will remove an existing tube if pre sent until it flush with the incoming end and re tighten the small Knurled Knob POWER FEED 11 LINCOLN A 9 INSTALLATION A 9 7 Insert inner Wire Guide groove side out over the two locating pins in the feed plate 8 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
36. RET POUR enrouler le c ble lectrode autour de n importe quelle partie See LES MACHINES A SOUDER A Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET A donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 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 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 d
37. ain a number of com ponents in addition to the drive rolls to optimize the wire feeder for aluminum wire feeding These components are specifically designed to protect the aluminum wire from abra sion and deformation thereby avoiding many common alu minum feeding problems POWER FEED 11 LINCOLN C 1 C 2 ACCESSORIES C 2 DESCRIPTION OF OPTIONAL CON TROL BOX PANELS A number of Optional Features are available for use with Power Feed 11 Some Installation information is provided in this section REFER TO THE INSTRUC TIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLATION OPTIONAL PANELS FOR CONTROL BOX The PF 11 Control Box is designed to accept two con trol panels and one door option Panels can be mounted in one of two positions Upper and lower Each Control Box is shipped with a Control Display CD panel installed in the upper position and a CV Gouge CV G panel in the lower position The CD panel must be installed in every Control Box The remaining panel can be one of the following CV G MX2 or MSP2 Note The CD panel must be installed in the upper position its harness is not long enough to allow instal lation in the lower position Similarly option panels must be installed 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 re
38. ar Some light pressure on the Control Box may be necessary to get the release bar to click into the mounting shaft groove POWER FEED 11 LINCOLN A 3 INSTALLATION A 3 CABLE CONNECTIONS CONTROL CABLE CONNECTIONS All system control cables are the same e All control cables can be connected end to end to extend their length e All system equipment must be connected to a con trol cable Welding systems using the Power Feed 11 offer previ ously unprecedented flexibility in the connection of system components This system uses the same type of control cable between each of the system compo nents Connections can be daisy chained from one system component to another Since communication over the control cables is done by a robust communi cations network the order of connection of the com ponents makes no difference The cables can be con nected anywhere that there is a mating connector CONTROL CABLE SPECIFICATIONS The cable is a 5 copper conductor cable in a SO type rubber jacket There is one 20 gauge twisted pair for network communications This pair has an impedance of approximately 120 ohms and a propagation delay per foot of lt 2 1 ns There are two 12 gauge conduc tors that are used to supply the 40 VDC to the net work The fifth wire is 18 gauge and is used as an electrode sense lead It is typically connected to the feed plate on the feed head when that feed head is active NOTE M
39. aximum cable length between any two nodes is 250 TYPICAL CABINET FEEDER CONNECTION The Control cable is connected from the Power Source to the Wire Feeder The Power Feed 11 comes standard with an 8 ft Control Cable CONTROL CABLE INSTALLATION 1 Connect the end of the control cable with the 5 pin cable plug to the mating receptacle on the power source With the pins and key aligned plug it into the power source rotate the threaded locking ring until the connector is completely fastened 2 Connect the end of control cable with the 5 socket end to the mating receptacle on the back of the wire feeder To connect the cable to the feeder aligning the pins and key plug it into the back of the wire feeder head rotate the threaded locking ring until the connector is completely fastened Note Depending on the location of the of the Wire Feeder relative to the Power Source a longer Control Cable or additional Control Cable s may be required See section 2 0 Optional Features for information on optional Control Cables 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 A work lead must be run from the negative power source output stud to the work piece The wor
40. d 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 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 11 LINCOLN E 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS FOSSIBEE CAUSE COURSE OF ACTION 14 Displays and or indicator lights a The encoders or switches may be Jlf 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 44 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
41. ding 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 11 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 source 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 11 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 char acteristics output voltage output current according to pre programm
42. dures 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 11 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 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 A CAUTION If for an
43. e fusibles Garder tous les couvercles et dispositifs de s ret leur place v v for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above 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 44 WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be fo
44. e with flow sensor kit for detailed instal lation instructions 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 instructions in the INSTALLATION section K1649 1 MOUNTING BRACKET HORIZONTAL The K1649 1 provides a bracket for mounting the Power Feed 11 horizontally on top of the Power Source Installation instructions are included with the bracket POWER FEED 11 LINCOLN D 1 MAINTENANCE D 1 MAINTENANCE Safety Precautions WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When inching with gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released 0 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 maintena
45. ection 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 44 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 11 LINCOLN E 11 TROUBLESHOOTING E 11 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 pispa shone ay yuwe teng eg An attempt was made to reprogram Check for potential electrical HF a CB or feed head but the program noise generators in the area Try did not verify removing the noise source and pro gramming again If the Err 020 still occurs either replace the EEPROM 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 PS No heart beat response from an If this occurs while
46. ed settings contained in the power source In constant current modes arc gouging stick TIG this control adjusts the output current 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 setup 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 volt age 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 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 welding 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 sec onds 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 system com ponents The WFS range for instance is dependent upon the gear range in the
47. for all units Permits selection of extended modes Note the factory shipped settings for Switch S2 are as follows PF 11 European Switches 1 2 amp 5 7 OFF Switches 3 4 8 ON PF 11 World Switches 1 3 amp 5 7 OFF Switches 4 8 ON O SETTING DIP SWITCHES IN THE WIRE DRIVE FIGURE A 4 qggqqy 8 4 9 GS CN There is one DIP switch bank on the control board of the wire drive It s labeled S1 and is located and ori ented as shown in Figure A 4 s1 S1 DIP Switch Bank on Wire Drive Control Board For software version S24468 1 grammar n O EE Tata poro mea ire drive ire drive Network Feed Head ID Assigns feed head number to wire drive 5 Network Feed Head ID LSB Assigns feed head number to wire drive 7 Switch position must match actual gear box ratio of wire drive Note the factory shipped settings for Switches 1 7 is OFF Switch 8 is ON POWER FEED 11 LINCOLN A 8 INSTALLATION A 8 WIRE FEED DRIVE ROLL KITS AND FAST MATE GUN ADAPTER GUIDE TUBES NOTE The maximum rated solid and cored wire sizes and selected drive ratios are shown on the SPECIFICATIONS in the front of this section The electrode sizes that can be fed with each drive roll and wire guide are stenciled on each part Check the kit for proper components Kit specifications can be found in the ACCESSORIES
48. 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 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 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 POWER FEED 11 LINCOLN B 4 OPERATION B 4 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 Control Box sec tion it is possible to reca
49. harged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry No C O D Orders l CHECK ONE I Please Invoice only if order is over 50 00 I Check or Money Order Enclosed U S Funds only I Credit Card ER Ce TTT Ge pes Mal LL Le THIS FORM TO ORDER sooks OR FREE INFORMATIVE CATALOGS Lincoln Welding School Titles Price Code Quantity Cost I ED 80 New Lessons in Arc Welding 5 00 L ener Information Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings 4 50 H Educational Video Information ____ menve Management 5500 M i Bee A New Approach to industrial Economics 5 00 NA Lames F Lincoln Arc Welding TPS American Century of John C Lincoln 5500 AC __ Si Foundation Book Information Welding Preheal Calculator 300 wes CT JFLF 518 Pipe Welding Charts 5450 eos I r C SUE efor Shipping Coss ifany l O _ Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Name Address Telephone Signature as it appears on Charge Card LE A A T TT 2 veel Keep your head out of fumes Use ventila
50. he 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 welding sequence burnback postflow etc European Only 4 Step Logic With Crater Fill OFF 1 Closing the gun trigger initiates the welding sequence preflow run in etc 2 Opening the trigger allows the wire to continue feeding before or after the welding arc is estab lished If the arc goes out the wire continues feed ing 3 Closing the trigger again cancels the interlock and the wire to continues feeding 4 Opening the trigger again ends the welding sequence burnback postflow etc With Crater Fill ON 1 Closing the gun trigger initiates the welding sequence preflow run in etc 2 Opening the trigger allows the wire to continue feeding before or after the welding arc is estab lished If the arc goes out the wire continues feed ing 3 Closing the trigger again cancels the interlock changes the wire feed speed and the Volts Trim to the Crater values and the wire continues feeding 4 Opening the trigger again ends the welding sequence 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 swi
51. he 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 11 LINCOLN B 10 OPERATION B 10 COMPONENT STATUS LIGHTS which component is causing the problem By using the status lights the operator can quickly pinpoint the system problem to a particular component See the following table for a complete listing and description of all status light conditions 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
52. igh risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder e 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 Lo plates to protect your eyes from sparks and TT 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 f
53. itches 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 S1 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 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
54. k 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 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 ELECTRODE CABLE INSTALLATION The Power Feed 11 comes with an installed electrode cable Connect the power source end of the cable to the power source output terminal of the desired polari ty The K1636 1 Power Feed 11 Europe electrode cable is equipped with a Twist Mate connector while the K1635 1 Power Feed 11 World is equipped with a lug connector Also for both models open the Wire Drive compartment door and check that the electrode cable lug is against the Feedplate and that the con nection is tight Any electrode cable replacement or extension should be sized according to the specifica tions given in the work cable connections section POWER FEED 11 LINCOLN A 4 INSTALLATION A 4 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 o
55. l 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 POWER FEED 11 LINCOLN B 1 OPERATION B 1 SAFETY PRECAUTIONS 44 WARNING 0 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 this installation Observe all additional Safety Guidelines detailed throughout this manual PRODUCT DESCRIPTION The Power Feed 11 is a high performance digitally controlled modular cabinet style 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 P
56. lable in lengths of 8 16 25 and 50 With input power disconnected from the power source install the Control Cable Assemblies per the instruction in INSTALLATION Cable Connections POWER FEED 11 LINCOLN os ACCESSORIES C 3 WIRE SPINDLE ADAPTERS K435 Permits 14 Ib 6 kg Innershield coils to be mounted on 2 51 mm O D spindles K363P Adapts Lincoln Readi Reel coils of electrode 30 Ib 14 kg and 22 Ib 10 kg to a 2 51 mm spin dle Durable molded plastic one piece construction Designed for easy loading adapter remains on spin dle for quick changeover GUN AND CABLE ASSEMBLIES A number of Fast MateTM air cooled and water cooled gun and cable assemblies as well as fume extraction models are available for use with the Power Feed 11 See the appropriate Magnum literature for detailed information K1536 1 WATER FLOW SENSOR KIT This kit is intended to be used as a means of stopping 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 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 com
57. lace CB mother PC board Microprocessor RAM Error in object Cycle power as in Err 211 If Err 212 board other than Control Box Such fis 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 CB mod This is an indication that a constant ule that contains the status LED current such as stick or gauge mode has been selected Turning the right encoder clockwise when in this state will activate output to Power Source Turning the right encoder counter clockwise will deactivate output 44 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 11 LINCOLN 822011 d31S r Id31S YN qa1snivis Na334S q33 096 Wels 39YNd SVD HONI 0109 DIAGRAMS MAIA LNOYS YO LOANNOO NNO eld Old dd ye 9 pig opisul pa3sed s apod Jen gt nued e 104 uue BeIp nads ay L F J qwunu po2o 1u uudinb y SAID Ju w ejd e JO 3u unued q 225 au 0 AUM 3 Q163 1 S weep eu y sjaued aunso us y JO uo uo aulyoeu y yenuew siy Aq parao s uypew IS 104 ayeINDDe aq jou Aew 1 AJUO 2U 1 J 1 104 S LWUe1Belp SIUL ILON
58. ll a given memory by quickly pulling and releasing the gun trigger 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 when ever the trigger is pulled a welding sequence pre flow run in etc begins so the electrode should not be allowed to contact the work piece CONTROL BOX PANELS SET 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 1s 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 Arc Control Unitless characteristic
59. llowed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page Installation u See ENEE ii Section A Technical Specifications sis uuu R uu uu uu n ua bio idad A 1 Safety Precautions sles mener ner S aaa Sasa sh A 2 Wire Feeder to Power Source Configurations A 2 Mounting on Top of the Power Source A 2 ele NEE A 2 On IHe E O0 gt xo z aayqa dia oracle ria tfno tee M A 2 Control Box Orientation 2 228224 KEEN a A RA A 2 Cable CONNEcCtONS S uu unu su y ga m iska a Egeter A 3 Control Cable Connections sn A 3 Control Cable Specifications r r nn A 3 Typical Cabinet Feeder Connection a A 3 Control Cable Installation e a ire A 3 Electrode Cable Connections cccccccceceeecceceeeeceeeeceeeeeecaececeseenaaeeeeeeseeaeeeeeeeeaeeeeees A 3 Electrode Cable Installation su A 3 Work Cable Connections ss A 4 Wire Drive Gear Ratio High or Low Speed A 4 Selecting the Proper Gear Ratio ss A 4 Changing the Wire Drive Ratio sis A 4 DIP Switch Setup EEN A 6 Setting DIP Switches in the Control Box A 6 Setting DIP Switches in the Wire Drive A 7 Wire Feed Drive Roll Kits sise A 8 Procedure to Install Drive Rolls and Wire Guides a A 8 Gun and Cable Assemblies U Uu e Gun Connection Guidelines cn nannn nn GMAW Shielding Ga A AAA LPG AGG ay m etanol etilo lado uapa elec Teen Optional Features Installation ss Optional Pane
60. ls for Control Bon General Panel Installation Guidelines Operational Safety Precautions miii li Product DeSCHIPTOM BEEE ETE E EAT ea Recommended Processes and Equipment B 1 NA O ua n a hurasta B 1 Control Box Operation iia illa tn B 1 Control Box Panels Upper Panel nseooseneeseeeneneeseenneresetnnsretrrtnssrettnntssttennntereeenseee B 1 Control Box Panels Set Up Controls Description B 4 Control Box P C Board Adjustments B 4 Control Box Setting Operating Limite B 5 Control Box Using Operating Limite B 5 Wire Drive Operation 1 u u H aa S Uncen eaten vie tia Pian a e aiee eae e B 6 Wire Drive Settings External sise B 6 Wire Drive P C Board Adjustments I r B 7 Wire REGU LONG 222 O EE B 7 Feeding Electrode and Brake Adjustment nn B 8 Drive Roll Pressure Setting us B 8 Gas Guard Regulator Settings B 8 OI ais RECKEN B 9 Wire GET Rea Ile Da Te EE B 9 Wire Feed Overload Protection ss B 9 Component Status Lights B 10 Status Light States pi cana B 10 EE Section C Drive Roll and Guide Tube Kits ss C 1 Other ACCESSONECS vision tl rta C 2 Maintenance cocina Section D Safely e EE D 1 Routine MAINTENANCE 2 2 uuu ua u a a au au aa aa us aaa aa D 1 Avoiding Wire Feeding Problems D 1 Periodic Maintenance dene Tanu a a ay ernest D 1 Procedure for Removing Feedplate from Wire Feeder
61. move 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 11 MX2 Panel This panel provides a selection of four weld modes CV MIG CV 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 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 K1640 1 Dual Procedure Memory Door Panel This panel provides two functions Dual Procedure and Memory Dual Procedure provides for setting and manual selection of two procedures Selecti
62. ms below Setting for Low Speed Setting for High Speed Y 8 4 9 GS N gt O Ol 8 4 9 GS N O S1 Si d Replace the left case side and screws and Mounting Bracket if required The PC board will read the switch at power up automatically adjusting all control parameters for the speed range selected POWER FEED 11 LINCOLN A 6 INSTALLATION A 6 DIP SWITCH SETUP ON Si 12 3 4 5 6 7 8 Hid SETTING DIP SWITCHES IN THE CONTROL BOX ON s2 12 3 45 67 8 There are two DIP switch banks on the mother board A BIS of the Control Box They are labeled S1 and S2 and are located and oriented as shown in Figure A 3 FIGURE A 3 S1 DIP Switch Bank on Control Box Motherboard For Software version S24456 1 or 1 Standard speed 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
63. nce 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 drive 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 section for roll chang ing instructions Wire Reel Mounting Readi Reels and 10 through 44lb 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
64. nflammables 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 9 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 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S
65. ning Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining ring groove on the spindle 5 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 6 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 7 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 8 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 9 Slide cage all the way onto the adapter until the retaining spring pops up fully OPERATION B 7 44 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 ELECTRODE 10 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 2 IN O D SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR y les RELEASE BAR GROOVES READI REEL INSIDE CAGE WIRES FIGURE Bi To Mount 10 to 44 Lb 4 5 20 kg Spools 12 300 mm Diameter or 14Lb 6 Kg Innershield Coils For 13 14 Ib 6 Kg Innershield coils a K435 Coil Adapter must be used 1 Open the Wire
66. ns 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 set 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 POWER FEED 11 LINCOLN B 5 OPERATION B 5 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 Sw
67. on 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 Installation of the door option can be done with only a Phillips screwdriver and a 3 8 wrench after the sys tem power is turned off Start by removing the upper panel for access to the PC board connector and the old door save the hinge parts Connect the door option PC board connector and the push on chassis ground wire route the leads through the access hole and install the door with the original hinge parts Reinstall the upper panel to complete the installation Detailed installation instruction are shipped with each door option K1543 K1544 AND K1545 INPUT CABLE ASSEMBLIES 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 16 25 50 and 100 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 60 duty cycle and is available in lengths of 8 16 25 and 50 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 60 duty cycle and is avai
68. onnectors self seal when disconnected c 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 K1536 1 Magnum Flow Sensor kit be installed This will prevent wire feeding if no water flow is present See ACCESSORIES Section for more information regarding this kit POWER FEED 11 LINCOLN A 10 GMAW SHIELDING GAS 44 WARNING CYLINDER may explode if damaged e Keep cylinder upright and chained to E support Keep cylinder away from areas where it may be damaged e Never lift welder with cylinder attached e Never allow welding electrode to touch cylinder e Keep cylinder away from welding or other live elec trical circuits BUILDUP OF SHIELDING GAS may a harm health or kill e Shut off shielding gas supply when not aL eee SEE AMERICAN NATIONAL STANDARD 2 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 Any shielding gas can be used that is recommended in the electrode s product literature at a maximum pressure of 60 psi 4 1 bar This may include such gasses as Argon Helium Nitrogen and blended gasses such Ar He Ar N2 Ar O2 Ar CO2 CO2 and Ar CO2 02 Connect a supply hose from the gas cylinder flow valve o
69. onsidered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distor
70. operator to quickly identify that the system is working properly or if not 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 The system component is not receiving input tioning correctly power or is faulty Green LED blink It should only blink for a few seconds while It should only blink for a few seconds until ing at a normal the system is mapping identifying compo the system component node has been rec rate nents If blinking continues every group may ognized If the blinking continues at least have a mapping error DIP switches may be one node in the group has a mapping error set incorrectly DIP switches may be set incorrectly The node or nodes with mapping errors will be blinking red e There may be too many components in the group All components in the group will be blinking green e The power source bus may not be avail able The bus may be being used to program another component e The LED s of the power source and the component being programmed will be solid green Red LED blinking Indicates a recoverable communication fault Indicates a recoverable communication fault at a normal rate The power source should automatically most likely caused by one of the following recover If it cannot recover
71. ower Feed 11 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 11 is available configured in both European and World models There are two features that distinguish the European from the World model The first is the 4 step trigger logic and the second is the type of electrode connection which is a Twist Mate on the European and a Lug on the World See later in this section for more details on the 4 step trig ger logic RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Feed 11 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 11 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 11 wire feeder is capable of welding at a 100 duty cycle continuous wel
72. r body 1 f Do not put your hands near the engine fan e Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side AR Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a h
73. rm the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 11 LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION 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 split 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 sary 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 44 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
74. rom durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 3 FUMES AND GASES a 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 5 b 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 products 5 c Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially
75. s 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 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 zones o l on pique le laitier 6 Eloigner les mat riaux i
76. se 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 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 QA 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 MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running
77. section FAST MATE GUN ADAPTER GUIDE TUBES Guide Tubes for Steel Wire The Power Feed 11 is supplied with 4 wire guide tubes which allow the I D of the Fast Mate gun adapter to be optimized for every wire size The vari ous size wire guide tubes are identified by the number of rings scribed toward one end of the tube and should be selected per the table below Wire Size Number of Rings 023 045 0 6 1 2mm 045 1 16 1 2 1 6mm 2 1 16 5 64 1 6 2 0mm 3 5 64 7 64 2 0 2 8mm 4 1 Guide Tubes for Aluminum Wire For optimum aluminum wire feeding the appropriate plastic lined guide tube should be used per the table below These must be ordered Wire Size 030 035 0 8 0 9mm 035 3 64 0 9 1 2mm 1 16 1 6mm PROCEDURE TO INSTALL DRIVE ROLLS AND GUIDE TUBES WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When feeding without Power Feed 11 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 0 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
78. tch 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 but neither the power source nor the drive motor will be energized POWER FEED 11 LINCOLN 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 1 Open the Wire Drive Compartment Door 2 Depress the Release Bar on the Retaining Collar and remove it from the spindle 3 Place the Adapter on the spindle 4 Re install the Retai
79. te Most Non Lincoln Guns can be connected to the Power Feed 11 provided the gun has a European Style Gun Connector GUN CONNECTION GUIDELINES General Guidelines The instructions supplied with the gun should be fol lowed when installing and configuring a gun What fol lows are some general guidelines that are not intend ed to cover all guns a Check that the drive rolls wire guide and gun adapter wire guide tube are proper for the elec trode size and type being used If not change them b Connect gun to gun connector making sure all pins and gas tube line up with appropriate holes in con nector Tighten gun by turning large nut on gun clockwise WATER COOLED GUIDELINES The Power Feed 11 comes equipped with coolant inlet and outlet connections on the front and back of the feeder The maximum water pressure permitted for use with the PF 11 is 100 psi a Using male quick connect fittings connect appro priate water hoses to the coolant inlet and outlet on the back of the feeder Connect the other ends of these hoses to the appropriate ports on your water cooling unit b Connect the gun hoses to the coolant inlet and out let on the front of the feeder In the event the water line fittings on your water cooled gun are incompatible with the female quick connects on the front of the Power Feed 11 male quick connects are provided for installation on 3 16 5mm hose Customer to provide appropriate clamps The feeder c
80. ter 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 direction 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 displayed 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 direction until the switch is released or the upper or lower limit is reached 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 tog gle switch Moving the switch bat up or down adjusts the displayed value in the corresponding direction Holding the switch in either direction will cause the display to move quickly in the corresponding direction until the switch is released or the upper or lower parameter limit is reached
81. the LED will be More than one control box UI in the solid red group All control boxes in the group will be blinking red e No control box UI in the group All nodes in the group will be blinking red e 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 e The feed head DIP switches may be set to zero The nodes with DIP switches set to zero will be blinking red eThe node bus may be off Red Green LED Indicates a recoverable hardware fault such Indicates a recoverable hardware fault such blinking at a nor as over temperature overload shutdown etc as over temperature overload shutdown etc mal rate 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 POWER FEED 11 LINCOLN B 11 OPERATION B 11 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 ware fault Contact your Local Authorized erable hardware fa
82. ther 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 3 0 85 mm2 3 0 85 mm2 When using an inverter type power source Use the largest welding electrode and ground cables that are practical At least 3 0 85 mm2 copper wire even if the average output current would not normally require it When pulsing the pulse current can reach very high levels Voltage drops can become excessive leading to poor welding characteristics if undersized welding cables are used WIRE DRIVE GEAR RATIO HIGH OR LOW SPEED The speed range capability and drive torque of the Power Feed 11 wire drive can be easily and quickly changed by changing the external drive gear The Power Feed 11 is shipped with both a high speed and a low speed gear As shipped from the factory the high speed low torque gear is installed on the feed er 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
83. ting assistance before you proceed POWER FEED 11 LINCOLN E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS FOSA CAUSE COURSE OF ACTION 10 Speed does not change when weld current flows Status lights 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 Ja 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 are solid green on both CB and feed head boards a Run in and weld speeds are set to the same value 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 fee
84. tion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals A 700 00 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only l IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add I 5 00 For order value up to 49 99 l 10 00 For order value between 50 00 amp 99 99 l 15 00 For order value between 100 00 amp 149 00 l For North America invoiced orders over 50 00 8 credit card orders if UPS is requested it will be invoiced or c
85. tion 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 e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a e Use ventilac o e exhaust o para remover fumo da zona respirat ria eEi APGR RT K350C UTC F n RBAPHECTIHIEBLTIA D ECETIA OF Bit ADAN A ARE eya 37128 else e S XACOER E 2743 MAS AH 7AA H4 587E ARBSHAIS a os Land dl CA al hia Ja d 4942 Jaial O L is Al AA ge Cal sag st e Turn power off before servicing e 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 e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas O Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas SOX FILA Y ERKE D PSB EPERA FE BFIVTFE WS o AUIRER egal HAS fc et AIR Aa AL k J y Je ghil Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas e N op rez pas avec les panneau
86. ult 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 11 LINCOLN C 1 ACCESSORIES TABLE C 1 DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4 Roll Drive 4 Driven Solid Steel Electrode 0 023 0 025 0 6 mm KP1505 030S 0 030 0 8 mm KP1505 030S 0 035 0 9 mm KP1505 035S 0 040 1 0 mm KP1505 045S 0 045 1 2 mm KP1505 045S 0 052 1 4 mm KP1505 052S 1116 1 6 mm KP1505 1 16S 5 64 2 0 mm KP1505 5 64 3 32 2 4 mm KP1505 3 32 Cored Electrode 0 030 0 8 mm KP1505 035C 0 035 0 9 mm KP1505 035C 0 040 1 0 mm KP1505 045C 0 045 1 2 mm KP1505 045C 0 052 1 4 mm KP1505 052C 1 16 1 6 mm KP1505 1 16C 0 068 1 7 mm KP1505 068 5 64 2 0 mm KP1505 5 64 3 32 2 4 mm KP1505 3 32 7 64 Lincore Hard Facing 2 8mm KP1505 7 64H 7 64 2 8mm KP1505 7 64 120 3 0mm KP1505 120 0 035 0 9 mm KP1507 035A 0 040 1 0 mm KP1507 040A 3 64 1 2 mm KP1507 3 64A 1 16 1 6 mm KP1507 1 16A 3 32 2 4 mm KP1507 3 32A Included with K1636 1 Power Feed 11 Europe only The KP1507 series of drive roll kits cont
87. utlet to the 5 8 18 female inert gas fitting on the back panel of the Wire Feeder See ACCESSORIES section for information regarding the optional Gas Guard Regulator Note Included with the K1636 1 Power Feed 11 Euro ONLY is a barbed fitting and union nut that can be installed on the 5 8 18 female inert gas fitting on the back panel of the Wire Feeder and allows for the connection of a 3 16 5mm I D gas hose Customer to provide appropriate clamps INSTALLATION A 10 LIFTING HANDLE The Power Feed 11 is shipped with a insulated Lifting Handle which can be mounted on the top or back of the Wire Feeder This handle is intended to be primar ily used for short term carrying of the Feeder While this handle is suitable for hanging the Feeder it is rec ommended that the Lifting Eyes also always be used when hanging the Feeder The procedure to mount the Lifting Handle is as follows 1 Turn Off the Welding Power Source 2 Open the Wire Drive Compartment Door and remove the wire reel if present 3 Using the appropriate socket and wrench 1 2 remove the 2 screws and nuts from either the mid dle top or middle rear of the Feeder The screws are black in color and about 6 5 apart 4 Using the hardware provided with the handle secure the handle in the desired position Note If it is desired to have handles in both the top and back locations an additional handle can be ordered Part Number S24131 POWER FEED 11 LINCOLN
88. 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 persists then replace the CB mother PC board 44 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 11 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 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 rep
89. ws and loosen but don t remove the 2 lower screws b Slide the Motor Gearbox to the UPPER SET OF HOLES FOR LOW SPEED LOWER SET OF HOLES FOR HIGH SPEED c Secure in position with flat washers lock wash ers and socket head screws that were previ ously removed and loosened 6 Re attach Feedplate and gas hose and gun leads if they were removed that was removed in Step 3 and reconnect the Electrode Cable Note The screws that secure the Feedplate to the Interface Plate must go thru the insulator bushings in the Feedplate 7 Close the Wire Drive Pressure Door and Wire Feeder s Compartment Door 8 Set the High Low Dip Switch on Feed Head PC board as follows a Remove the left case side as follows Remove 4 screws that directly secure the case side Loosen the 3 screws that secure the lower skid rail This will free the case side edge and allow it to be lifted up and removed Note PF 11 s that have been installed horizontally on top of the Power Source will need to remove the Mounting Bracket in order to access the the left case side b Locate the 8 position DIP switch S1 on the Feed Head PC board The setting will be made on the bottom most switch DIP switch 8 c Using a pencil or other small object to slide the switch left to the OFF position when the low speed gear is installed Conversely slide the switch right to the ON position when the high speed gear is installed Refer to the diagra
90. x ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas V J P D 7 32 t p L Z CRMBIEE U uA CG F uv CRRRIARRARS SER Ro exo Yel Yala AHSA DRAS L t cals 13 gal D Jai ve Aale Cut Al ll ta WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it ies BR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBO X HD OHBRBEEK BMA ETHRMLTF EW ECL TCHHORERME HST F uv HAMAD SUCER HN EH BB RES AMEN RRR sy J A BS 55 EJ ECKE o HZ SEE oc ZHAXIAINE nie SAISIR FA Sigi CHAS EPA BES Aal veel Z d alayla 2 y Llana J AAL all oig Gail all lala ay ge L WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da O Aislese del trabajo y de la tierra O Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension
91. y 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 11 LINCOLN E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE TAVSE COURSE OF ACTION 7 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 8 No control of wire feed a Defective motor tach or control All status lights are solid green PC board or harness Check for Preset WFS is adjustable on Control loose or faulty connections on Box motor tach See Wiring Diagram 9 Wire feed motor turns and sole a 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 44 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 troubleshoo

Lincoln Electric IM613-B User's Manual

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