Lincoln Electric 4R220 Welder User Manual
Contents
1. AutoDrive 4R220 LINCOLN 5 L15157 5 AutoDrive 48220 LINCOLN B Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Chinese Korean Do nottouch electrically live parts 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 d a Aislese del trabajo y de la tierra e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se e terra 4580208388 2 1808 288040 9 8 7 22 5 86168 ATUSRELTFEL DERRRBAR k eri 5888 FY sE au ong HIE oaa Y 6 PERCHE T All DE dus ule Y ae Keep flammable materials away e Mantenga el material combustible fuera del rea de2. erret rta ER ae EIER isadeasepedasaeteas A 2 LOCATION E 2 Weld Cable 2 Coaxial Weld 06 A 3 Wire Brive Cable anne reve eines 4 shielding cei eerie tate tin see e A 5 Procedure to Install Drive Rolls and Wire Guides A 6 Pressure Arm Adjustment Conduit 7 System Set 0 8 lcu Section B Safety Precautions B 1 Graphic Symbols that appear on this Machine or in this B 1 Detinition ot Welding 2 0 2 Recommended Processes Equipment Limitations Recommended Power Sources B 2 qM Section C Optinal Kits and 26005500 C 1 Drive Roll Kits 500 C 1 Accessories 2 3 Section D Safety Precautions iieri eet EE dene ee bI eet ides Er eR eee rete D 1 Routine Maintenance tai D 1 Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 E 3 Wiring Diagram amp Dimension Section F 61
3. Electrode Wire Feeder AutoDrive 4R220 LINCOLN B 4 INSTALLATION 4 WIRE DRIVE CABLE 1785 Wire drive cables are used to connect power sources and control boxes to remote wire drives The cables have a 14 pin connector at each end Both ends of the cable have a collar and the cables cannot be daisy chained to make a longer cable POWER SOURCE WIRE FEEDER JO IO OK OB HO NO OL Oc CO LO ON OH GO OM OD POWER SOURCE WIRE FEEDER Reserved 2A Differential Tachometer eserved Differential Tachometer 15VDC Tech Supply Differential Tachometer Tachometer Common Reserved Reserved Reserved Reserved 1A Differential Tachometer 1A Differential Tachometer gt gt zzl 4z ofr ob 3 52 2 Pad AutoDrive 4R220 LINCOLN 5 5 INSTALLATION 5 SHIELDING GAS CONNECTION A WARNING CYLINDER may explode if damaged e Keep cylinder upright and chained to support e Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached Never allow welding electrode to touch cylinder e Keep cylinder away from welding or other live electrical circuits e BUILD UP OF SHIELDING GAS MAY 3 HARM HEALTH OR KILL Shut off shielding gas supply when not in use See American National Standard Z 49 1 Safety in Welding and Cutting Published by the American Welding S
4. 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 PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER TRANSFORMATEUR a Utiliser bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre 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 chau
5. sjeued y euo uo y LL pelsed si epoo 104 y siu Aq 104 elelnooe eq jou Aew y AjUO seoueiejei JO SI SIUL c9SLc IN HOLO3NNOO 30 3015 QV31WNOHd Sv 39N3003 O9NIH38IARN ALIAVO Quvoa 2440 3015 LN3NOdIAOO Sv 5 ONIH38IRN ALIAVO qaau u H8 MOTI3A 0 31IHM M 8 40109 QV31 46513 d3d 5109 15 1V9IH1O3T3 qION310S 9 8 005 8 SYD VGP8 VEY8 VSIG 6 0 8 9 8 9 M B 8 lp 8 6 gt 5 0000 0000 gt 9 gt 0000 0000 XOauva9 g g t TE YN VN z 766 MOTISA Logr oosr 21 gt HOWL 6 6 31V 120333 Q8 Od 39V3H31NI HOV L DIAGRAMS 0624 1 SNIHIA AutoDrive 48220 LINCOLN 3 F 2 DIMENSION PRINT m 2 04
6. 4 ROLL DRIVE Steel Wires 1505 0305 023 030 0 6 0 8mm Includes 4 V groove KP1505 035S 035 0 9mm drive rolls and inner 1505 0405 040 1 0mm wire guide KP1505 045S 045 1 2mm Cored Wires KP1505 035C 030 035 0 8 0 9mm lncludes 4 Knurled KP1505 045C 040 045 1 0 1 2mm drive rolls and inner wire guide Aluminum Wires 1507 3 64 3 64 1 2mm Includes 4 polished U groove drive rolls outer wire guide and inner wire guide AutoDrive 4R220 LINCOLN B 2 ACCESSORIES 2 Gun Receiver Bushing for guns Includes Gun receiver bush with K466 1 Lincoln gun connec ing set screw and hex key tors Innershield and Subarc guns wrench Gun Receiver Bushing for guns with K466 2 K466 10 Lincoln gun Includes Gun receiver bush connectors Magnum 200 300 400 ing with hose nipple set screw guns and compatible with Tweco and hex key wrench 2 4 Gun Receiver Bushing for guns Includes Gun receiver bush with K613 7 Lincoln gun connec ing with hose nipple set screw tors Magnum 550 guns and com and hex key wrench patible with Tweco 5 Gun Receiver Bushing for gun Includes Gun receiver bush K1500 4 with K466 3 Lincoln gun connec ing with hose nipple set screw tors compatible with Miller guns and hex key wrench Includes Gun receiver bushing K1500 5 Gun Receiver Bushing compatible with hose nipple 4 guide tubes with Oxo guns set screw and hex
7. CAUSE COURSE OF ACTION Output Problems Variable or hunting arc Check for proper size contact Make sure the contact tip is not worn free of spatter and not melt ed Clean and tighten all electrode and work connections Verify the proper polarity is being used for the weld procedure Make sure the proper electrode Stick out is being maintained Check the gas flow rate and mix ture Verify the gun bushing is tightly mounted to the wire drive Verify the gun is tightly mounted to the gun bushing Verify the electrode lead is con nected to the proper connection block on the feed head Inspect the motor for worn brush es The motor overload errors occur Check for sharp bends in the gun liner and conduit Examine the contact tip for wear and proper size Replace as nec essary Check the gun liner and conduit The welding electrode should slide easily through both Verify the proper gun liner is installed Reduce the pressure arm setting 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 AutoDrive 4R220 LINCOLN 5 Jequunu epoo y 3ueureoe dau e 104 2011S eui ol 6 9 s eu J
8. ELECTRIC AND MAGNETIC FIELDS 353 may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electr
9. key wrench Gun Receiver Bushing for Lincoln Includes Gun receiver bushing Fast Mate guns with trigger connector K515 04 Requires K1546 1 0 Requires 9467 Incoming Bushing for Lincoln Conduit 025 1 16 0 6 1 6mm Includes Incoming bushing and wire Compatible with Electron hex key wrench Beam Conduit AutoDrive 4R220 LINCOLN 5 C 3 ACCESSORIES K2175 1 500 Ib Accu Pak Box Payoff Kit K2175 2 1000 Ib Accu Pak Box Payoff Kit K895 2 Rotary Wire Dispenser K836 1 Dereeler Adapter K884 5 Accu Trak Drum Payoff Kit 20 inch diameter K884 6 Accu Trak Drum Payoff Kit 23 inch diameter K1796 xx Coaxial Cables Includes 1 cable of length feet 14 pin connectors on both ends Cable length can not be extended by connecting K1785 cables together K2593 xx Coaxial Cables K1785 xx Wire Drive Cables Includes 1 cable of length feet 14 pin connectors on both ends Has collars at both ends Used with FANUC arms that have an integrated cable K2709 xx Wire Drive Cables Includes 1 cable of length feet 14 pins connectors on both ends May be daisy chained to make a longer cable Used with FANUC arms that do not have an integrated cable Wire Straightener Includes 1 wire straightener AutoDrive 4R220 LINCOLN 5 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the welding pow
10. to the arc rays or to hot spatter or metal 40 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 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
11. toxic gas and other irritating prod ucts 5 d Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 5 f LINCOLN 5 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Jan 09 SAFETY WELDING and CUTTING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks 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 conta
12. trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos 9115215 R8 T THEA 48 APIX AL gll a e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo eU 5 712 0 78 dis due gDay cl READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing z
13. 3 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS AutoDrive 48220 2685 1 VOLTAGE CURRENT RATED OUTPUT 104 F 40 DUTY CYCLE AMPERES MOTOR POWER WATTS GEARING WIRE FEED SPEED RANGE WIRE SIZE GMAW FCAW K2685 1 50 1200 ipm 023 1 16 50 1200 ipm 035 5 64 0 8 30 5m min 0 6 1 6mm 1 3 30 5m min 0 9 2 0mm PHYSICAL DIMENSIONS HEIGHT WIDTH LENGTH WEIGHT 10 43 Inches 10 07 Inches 9 92 Inches 20 9 Ibs 265 mm 256 mm 252 mm 9 5 kg TEMPERATURE RANGE OPERATION 40 F to 104 F 40 C to 40 C STORAGE 40 F to 185 F 40 C to 85 C AutoDrive 4R220 LINCOLN 5 2 INSTALLATION A 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL Turn the input power OFF at the welding power source before installation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform mainte nance work LOCATION Firmly secure the AutoDrive 4R220 wire feeder to a robot arm or fixture See L15169 iB and L15169 1 iC Mechanical Install
14. IM945 AutaDrive 4dR22U 2009 For use with machines having Code Number 11455 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful opera tion 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 5 9001 Gun Designed and Manufactured Under a Quali CERTIFICATE NUMBER 30273 LINCOLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS 1 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SER
15. IOUS 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 of Safety in Welding amp Cutting ANSI Standard 249 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 4 A 11 To avoid scalding do not remove the powered equipment 24 67 44 radiator pressure when the engine is hot 1 8 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 40
16. 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 Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves
17. RSE OF ACTION RSE OF ACTION The wire feeder does not feed wirel 1 Verify the power source is turned and the drive rolls do not spin on Verify the circuit breaker for the wire feeder on the power source has not tripped Verify power is being supplied to the wire feeder The wire feeds erratically Verify the correct drive rolls and inner wire guide are installed in the wire drive Check for sharp bends in the gun liner or conduit Examine the contact tip for wear and proper size Replace as nec essary Check the gun liner and conduit The welding electrode should slide easily through both Verify the proper gun liner is installed Verify the pressure arms are set properly Too much pressure may crush the wire Inspect the motor for worn brush es No shielding gas Verify the gas supply is turned on Variable or hunting arc and not empty Check the gas hose for cuts Make sure it is not crushed Verify the shielding gas hose is connected to the gun bushing or welding gun 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 AutoDrive 4R220 LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS
18. The flow regulator is adjustable Adjust it to the flow rate recommended for the procedure and process being used before making a weld AutoDrive 4R220 LINCOLN B 6 PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES WARNING 9 ELECTRIC SHOCK can kill Turn the input power OFF at the weld ing power source before installation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released Do not operate with covers panels or guards removed or open Only qualified personnel should perform mainte nance work To remove drive rolls and wire guides 1 Turn power off at the welding power source 2 Remove the outer wire guide 3 Rotate all of the triangular rings to the unlocked position UNLOCKED POSITION LOCKED POSITION INSTALLATION 4 Open the idle arms 5 Remove the drive rolls and inner wire guide To install drive rolls and wire guides 1 Turn off power at the welding power source 2 Open the idle arms 3 Assemble the inner wire guide INNER WIRE GUIDE DRIVE ROLLS OUTER WIRE GUIDE 4 Slide the drive rolls onto the drive hubs 5 Close the idle arms 6 Rotate all of the triangular rings to the locked posi tion 7 Assemble the outer wire guide 8 Adjust the pre
19. ation Instructions which are supplied with this Instruction Manual in the literature package Mount only in a dry environment WELD CABLE SIZE Table A 1 located below are copper cable sizes rec ommended for different currents and duty cycles Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop TABLE A 1 RECOMMENDED CABLE SIZES RUBBER COVERED COPPER RATED 167 F or 75 C AMPERES PERCENT 0 to 5OFt 0 to15m 2 1 1 1 1 CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES 50 to 100Ft 100 to 150 Ft 150 to 200 Ft 200 to 250 Ft 15 to 30m 30 to 46m 46 to 61m 61 to 76m 2 2 2 1 2 2 2 1 4or5 3 2 1 3 3 2 1 3 3 2 1 2 1 1 1 1 1 1 1 1 1 1 0 Tabled values are for operation at ambient temperatures of 104 F 40 C and below Applications above 104 F 40 C may require cables larger than recommended or cables rated higher than 167 F 75 C AutoDrive 4R220 LINCOLN 5 3 INSTALLATION COAXIAL WELD CABLE Coaxial welding cables are specially designed welding cables for STT and pulse welding Coaxial weld cables feature low inductance allowing fast changes in the weld current Regular cables have a higher inductance which Electrode may distort the STT waveshape Inductance becomes more severe as the weld cables become longer Coa
20. cision die cast aluminum frame A right angle gear box efficiently transfers motor power for both high torque and high speed The AutoDrive 4R220 features a powerful motor with an efficient two stage gearbox This feeder is best for feeding larger diameter wires pulling wire through long conduits and in applications requiring extra ruggedness A door covers the wire drive pro tecting it from dust General Functional Description A high resolution tachometer precision for wire feed ing forwards and in reverse For more information go to the following Web site http content lincolnelectric com pdfs products literature RoboticFeederSelectionChart pdf RECOMMENDED PROCESSES GMAW FCAW STT PROCESS LIMITATIONS K2685 1 AutoDrive 4R220 Maximum wire size 1 16 1 6mm EQUIPMENT LIMITATIONS K2685 1 AutoDrive 4R220 Maximum GMAW gun length 10 3 1m Maximum FCAW gun length 15 4 6m Maximum wire drive control cable length 100ft 31m Robot and power source software may need to be updated Drive rolls are not included with the feeder Mounts to FANUC ArcMate100iC arms Mounts to FANUC ArcMate100iB arms Maximum Conduit Length 50 Ft 15m RECOMMENDED POWER SOURCES Power Wave F355i Power Wave 455 all models Power Wave 455 STT M Power Wave 655 R Power Wave 400i AutoDrive 4R220 LINCOLN 5 C1 ACCESSORIES 1 OPTIONAL KITS AND ACCESSORIES DRIVE ROLL KITS
21. e with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Jan 09 i SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans 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 r
22. econd column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the welding power source before installation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform maintenance work 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 AutoDrive 4R220 LINCOLN B 2 TROUBLESHOOTING 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE COURSE OF ACTION SYMPTOMS CAUSE COU
23. efroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie 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
24. er source before installation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Do not operate with covers panels or guards removed or open Only qualified personnel should perform main tenance work ROUTINE MAINTENANCE To Install or remove the AutoDrive 4R220 for servicing See Installation Section of this Instruction Manual AutoDrive 4R220 LINCOLN B 1 TROUBLESHOOTING 1 HOW USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The s
25. guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas OSIL PHI ERUH L AEE CRERTMRALARS x e gdo yal SAME culs 13 jall a Jus 6 AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese Chinese x a LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 8658860 lt 8 1 gt 82 018 5493807780 TL TRHORESRME EDT FSU DES AE RH BA DL JR RE EX 1 FR B9 SR IS 3E EROR ST NA 5 01 SSE SIA EFM canal gll Jb al 4 il LINCOLN ELECTRIC World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
26. hing Insulate yourself from work and ground Always wear dry insulating gloves Do not operate with covers panels or guards removed or open FUMES AND GASSES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away ARC RAYS can burn Wear eye ear and body protec tion SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN UAL B 1 THIS MACHINE OR IN THIS MANUAL po U U2 l4 l2 AutoDrive 48220 LINCOLN 5 WIRE FEEDER POSITIVE OUTPUT NEGATIVE OUTPUT INPUT POWER DIRECT CURRENT OPEN CIRCUIT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION 2 OPERATION B 2 DEFINITION OF WELDING TERMS GMAW Gas Metal Arc welding FCAW Flux Core Arc Welding STT Surface Tension Transfer PRODUCT DESCRIPTION General Physical Description The AutoDrive 4R220 wire feeders are powerful yet compact wire drives for robotic and hard automation applications The MAXTRAC 4 roll wire drive gives steady feeding of all wire sizes and types The drive features split wire guides tool less drive roll changing dual spring pressure arms and changeable gun bushings all mounted in a pre
27. iners until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding powe
28. never you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page INSTANATION Section A Technical SpecifiGallOlls 5 25 2 tantu titt etra ertet tic snp nunt tee ans A 1 Safety Precautioris
29. ociety Maximum inlet pressure is 100 psi 6 9 bar Install the shielding gas supply as follows 1 Secure the cylinder to prevent it from falling 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve out let A Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench Note if connecting to 100 CO cylinder insert regulator adapter between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seated for connection to the CO cylinder 5 Attach one end of the inlet hose to the outlet fitting of the flow regulator Attach the other end to the welding system shielding gas inlet Tighten the union nuts with a wrench Before opening the cylinder valve turn the regulator adjusting knob counterclockwise until the adjusting spring pressure is released 7 Standing to one side open the cylinder valve slowly a fraction of a turn When the cylinder pressure gage stops moving open the valve fully 8
30. ode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded 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 5 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 Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control
31. one Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria 6 20 55 42 29 CRACVHEL TIMELTFEL CTPA ER e EUFOR E GE FR IR 802 e SA7I28 887 AS 2244214 55218 A g IdAIg oe daly sui jaa yi 6 e ox uu 44 ge gall 4 9 e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarheiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e 2722 POR FE o e 5580 AHS Gil Juill Do not operate with panel open or guards off No operar con panel abierto
32. r source for pipe thawing LINCOLN 5 CYLINDER may explode if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A 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 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordanc
33. ssure arms to the recommended setting AutoDrive 4R220 LINCOLN B 7 PRESSURE ARM ADJUSTMENT WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the weld ing power source before installation or changing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger electrode and drive mechanism are hot to work and ground and could remain energized several sec onds after the gun trigger is released Do not operate with covers panels or guards removed or open Only qualified personnel should perform mainte nance work The pressure arm controls the amount of force the drive rolls exert on the wire Proper adjustment of the pressure arm gives the best welding performance Set the pressure arm as follows See Figure A 3 Aluminum wires between 1 and 3 Cored wires between 3 and 4 Steel Stainless wires between 4 and 6 FIGURE A 3 LOADING WIRE WARNING Keep hands hair clothing and tools away from rotating equipment Do not wear gloves when threading wire PT or changing wire spool Only qualified personnel should install use or service this equipment INSTALLATION CONDUIT INSTALLATION The K1546 xx series of conduits are compatible with K515 xx K565 xx Wire Wizard and Electron Beam Technologies conduits To install conduit to the wire drive 1 Slide the conduit bushing into the feed plate and secure with the se
34. ssures montantes Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN 5 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 CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for an
35. t screw 2 Slide the conduit into the bushing and lock in place with the thumb screw SET e T THUMB CONDUIT BUSHING CONDUIT AutoDrive 4R220 LINCOLN B 8 INSTALLATION SYSTEM SET UP SINGLE ARM SYSTEM SET UP A 8 ezis alqeo 10 ejqe ol esues s 1 Jepead M M 68 1 9 9 88y N 12 esuas jeuondo L 6992 00 Jemod 2 1x 2 1X MumouV Ieuualul v1 M do peleJ6alul Jellonuoo VI0gf d 91001 IWY 91001 eleNouV umous 18109 oyim ozzy ony 2 7 XX 20S LM XX SO0S LH LINCOLN ELECTRIC AutoDrive 4R220 1 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE WARNING ELECTRIC SHOCK KILL Unless using COLD FEED fea ture when feeding with gun trig ger the electrode and drive mechanism are always electri cally energized and could remain energized several sec onds after the welding ceases Do not touch electrically live part or electrode with skin or wet clot
36. xial weld cables are recommended for STT weld ing especially when the total weld cable length elec trode cable work cable exceeds 50 feet 7 6m See Work Table A 2 A coaxial weld cable is constructed with multiple small leads wrapped around one large lead The large inner lead connects to the electrode stud on the power source and the electrode connection on the wire feeder The small leads combine together to form the work lead one end attached to the power source and the other end to the work piece To install 1 Turn the input power off at the welding power source 2 Connect one end of the center lead to the power source electrode connection and the other end to the wire feeder electrode connection Connect the outer lead bundle to the power source work connection and the other end to the work piece Minimize the length of any work lead extension for best results Insulate all connections CD TABLE 2 RECOMMENDED CABLE SIZES RUBBER COVERED RATED 75 C COAXIAL CABLE LENGTH Duty Amperes Cycle 0 to 25 Ft 25 to 50 Ft 50 to 75 Ft 75 to 100 Ft VO O 250 1 1 1 0 350 60 v0 0 Tabled values are for operation at ambient temperatures of 104 F 40 C and below Applications above 104 F 40 C may require cables larger than recommended or cables rated higher than 167 F 75 C Power Source Work Electrode Coaxial Weld Cable
37. y customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whe
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