Lincoln Electric POWER WAVE WELDING SYSTEMS User's Manual
Contents
1. M 16 18 ft Generic 75 1200 ipm 0 6 1 6 0 9 2 0 Boom Packagel 1 9 30 5 m min Both gears included 12 ft Zipline Ready Pkg 4 16 ft Zipline Ready Pkg 8 8x 10x 16 5 3 Wire Drive Only 222 x 254 x 419 1 Includes wire drive control box 8 ft Linc Net control Requires wire drive to control box Linc Net cable and weld cable and wire reel stand For 8 9 ft boom K1543 16 2 Includes wire drive control box 8 ft and 25 ft Linc Net For 10 18 ft boom K1543 25 control cables 4 Boom ready wire feeder for installation on a Zipline boom See bulletin E8 201 LINCOLN ELECTRIC A CLOSER LOOK Power Feed 10 Dual Control Box Large Easy To Read Digital Meter Large Easy To Use Wire Feed Speed Control Amperage Dual Head Select Panel Standard on Power Feed 10 Dual Models Weld Mode Selector Switch Standard on Power Feed 10 and 10 Dual SYSTEM SELECTION Typical MIG welding systems Power Wave 455 Power Feed 10 Industry Standard This is the ideal system for MIG and flux cored welding Power Wave 455 power source Power Feed 10 wire feeder K1541 2 045 Drive Roll Kit KP 1505 0455 Magnum 400 Gun 8 Cable asbly K471 21 Gas Regulator Adjustable Power Wave 455 Power Feed 10 Deluxe Pulse System For the ultimate in pulsing performance this system provides the options and flexibility needed for multiple processes and pulsing Power Wave 42. 55 power source Power Feed 10 wire feeder Undercarriage Dual Procedure Memory Panel MSP2 Pulse Panel Swivel Platform 045 Drive Roll Kit Magnum 400 Gun amp Cable asbly Gas Regulator Adjustable KP1505 045S K471 21 Large Easy To Use Voltage Trim Control Optional Procedure Control Panel Area Optional Process Control Panel Area Power Wave 455 Power Feed 10 Dual Deluxe Pulse System Power for those demanding jobs A dual feeder for running two different wires from the same power source Power Wave 455 power source Power Feed 10 Dual wire feeder Undercarriage MSP2 Pulse Panel 045 Drive Roll Kit 1 16 Cored Drive Roll Kit Magnum 400 Gun amp Cable asbly Magnum 550 Gun amp Cable asbly Gun Receiver Bushing for Magnum 550 Gun Connector Kit for Magnum 550 Gas Regulator Adjustable K1542 12 KP1505 045S KP1505 1 16C K471 210 Fully assembled no gun connector required Two required OPTIONAL CONTROL PANELS PROCEDURE CONTROL PANELS POWER FEED 10 Di EOCENE m V i tart HEAD Eh PAE rp HAD PROZEDURE B g PCAC ELE mm al POWER FEED 10 DUAL POOPIE DUAL PROCEDURE PANEL This panel stores two procedures in memory The user may select procedure A or B at the switch with a separate gun mounted switch or while welding with any welding gun Order K1542 5 DUAL PROCEDURE MEMORY Six different welding procedures and processes may be
3. Innershield gun and Magnum 200 300 and 400 Guns with Tweco 5 e Guns with Miller connectors cable assembly gun and cable assemblies connectors for new longer connectors with K466 10 connector kit Fast Mate gun and cable assembly with K489 2 Guns with Tweco 2 3 Fast Mate Adapter Kit and 4 connectors Magnum 550 gun and cable This gun receiver bushing assembly with K613 1 comes standard with each feed head K1500 1 K1500 2 K1500 3 K1500 4 K489 7 MAGNUM GUNS The following guns come pre assembled with liner and gun connector that is compatible with the Tweco 2 4 gun receiver bushing K1500 2 They con nect directly to the standard Power Feed 10 and 10 Dual Gun cables are 15 ft length K471 21 Magnum 400 035 045 K471 22 Magnum 400 052 1 16 K471 23 Magnum 400 1 16 5 64 K497 20 Magnum 200 025 030 K497 21 Magnum 200 035 045 Connector Kit for Feed Plate Gun Receiver Magnum Guns Bushing K1500 X jE K1500 2 comes standard with feed head as shown DRIVE ROLLS AND SPLIT WIRE GUIDE KITS 4 Roll and Split Wire Guide Solid Steel Wire Smooth V Groove 023 030 0 6 0 8mm Solid KP1505 030S 035 0 9mm Solid KP1505 035S 040 045 1 0 1 2mm Solid KP1505 045S 052 1 4mm Solid KP1505 052S 1 16 1 6mm Solid KP1505 1 16S Cored Steel Wire Knurled V Groove 030 035 0 8 0 9mm Cored KP1505 035C 040 045 1 0 1 2mm Cored KP1505 045C 052 1 4mm Cored
4. KP1505 052C 1 16 1 6mm Cored KP1505 1 16C 7 64 2 8mm Hardfacing Smooth U Groove KP1505 7 64H Cored or Solid Steel Wire Knurled V Groove 068 072 1 8mm KP1505 068 5 64 2 0mm KP1505 5 64 3 32 2 4mm KP1505 3 32 7 64 2 8mm cored only KP1505 7 64 120 1 8 3 2mm cored only KP 1505 120 Aluminum Wire Smooth U Groove 035 0 9mm KP1507 035A 040 1 0mm KP1507 040A 3 64 1 2mm KP1507 3 64A 1 16 1 6mm KP1507 1 16A 2 4mm KP1507 3 32A For Aluminum Wires For Solid and Cored Wires KP1507 KP1505 LINC NET CONTROL CABLES These come standard with both bench and boom versions of the Power Feed 10 and Power Feed 10 Dual wire feeders The Linc Net con trol cable has several advantages over existing control cables e Common cable for all parts The same cable can be used between the power source and wire feeder in a bench system and between the power source control box and wire drive in a boom system RECOMMENDED OPTIONS SPINDLE ADAPTER For 14 Ib 6 kg Innershield Coils Permits 14 Ib 6 kg Innershield electrode coils to be mounted on 2 51mm O D spindles Order K435 COIL ADAPTER 60 Ib Coil Adapter Adapts 60 Ib Lincoln coils of electrode to 2 51mm spindle Order K1504 1 10 Extension cord flexibility These control cables can be connected end to end for length flexibility A single custom length cable is no longer needed Extended l
5. POWER WAVE WELDING SYSTEMS WITH POWER FEED 10 AND 10 DUAL ll Premium MIG Welding Systems JE ON JARO T5 POWER WAVE WELDING SYSTEMS Simple Innovative Technologically Advanced These are all words that describe the Power Wave welding systems These next generation systems utilize Waveform Control Technology for the finest welding arc in the industry POWER SOURCE The Power Wave 455 is a high efficiency inverter designed for unprecedented ease of use and performance Sophisticated software in the unit controls the welding waveform for reduced arc spatter fumes and an exceptionally smooth arc WIRE FEEDER The Power Feed 10 and the Power Feed 10 Dual set the standard for easy to use rugged wire feeders They are perfectly matched for use with the Power Wave 455 resulting in a simple high performance welding package that is built to last 2 The Power Feed 10 and the Power Feed 10 Dual wire feeders feature easy to understand controls and the Lincoln four driven roll feed head These wire feeders have the strength and speed for the most demanding feeding applications whether it s for high speed or for large diameter wires Choose Power Feed 10 Dual when applications require two different wires to be utilized with no changeover time ADVANTAGE LINCOLN SYSTEM WIDE e Power Wave welding performance in a simple easy to use system e Set up flexibility with one control cable that connects a
6. ely mounted Straightens cored wire up to 1 8 3 2mm and solid wire up to 3 32 2 4mm Incoming and outgoing bushings are compatible with existing incoming and gun receiver bushings Order K1733 1 K1733 1 11 LINCOLN ELECTRIC SOFTWARE Wave Designer Software Wave Designer Pro Software tracks arc power arc resistance and Wave Designer software allows you to All the features of Wave Designer plus energy input Order K1705 2 program your own waveforms It puts Arc Scope the arc analysis tool for the power of waveform control in your those who need to monitor more than For more information request hands allowing you to customize voltage and current Arc Scope also literature S2 20 Lincoln s highly successful welding waveforms to meet your exact needs Once you have made the simple connection from your PC to your Power Wave 455 designing a wave form is easy Two software packages are available Wave Designer Software Permits manipulation of several wave shape parameters including peak current background current peak pulse width and pulse Allows for optimization of arc length Order K1705 1 Customer Assistance Policy The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equipment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric f
7. engths These cables can be connected up to 200 ft between any 2 components This allows more flexibility in locating the power source and wire feeder Ordering Information Linc Net Receptacles Provides Linc Net receptacles for converting a Power Feed 10 bench model to a boom model Order K1548 1 READI REEL ADAPTERS 30 Ib 14 kg Readi Reel Adapter Adapts 22 30 Ib 10 14 kg Lincoln Readi Reel coils of electrode to 2 51mm spindle Order K363P 60 Ib 27 2 kg Adapter Adapts 50 60 Ib 22 7 27 2 kg Lincoln Readi Reel coils of electrode to 2 61mm spindle Order K438 Control Cable Only K1543 8 8 ft cable length K1543 16 16 ft cable length K1543 25 25 ft cable length K1543 50 50 ft cable length K1543 100 100 ft cable length Control and Weld Cables 4 0 size K1544 8 8 ft cable length K1544 16 16 ft cable length K1544 25 25 ft cable length K1544 50 50 ft cable length Plastic Wire Cover Protects wire from dust and dirt and provides electrical isolation For up to 44 Ib wire packages Order K1634 1 For up to 60 lb wire packages Order K1634 2 Water Connection Kit Includes guick connect fittings on front and back of wire drive for use with water cooled guns and Magnum Coolers Kit provides for one gun Order K590 6 Swivel Platform Mounts to the lift bail on the power source and bottom of the Power Feed 10 Wire feeder may be lifted off if needed Compatible with Lig
8. ht Duty Caster Kit Includes lazy susan parts tray Order K1557 1 Power Feed 10 only K1557 1 RECOMMENDED OPTIONS Caster Kit Light Duty Mounts to the wire reel stand on the Power Feed 10 and Power Feed 10 Dual Allows for easy movement of wire feeder Order K1556 1 1 M r F K1556 1 Insulated Lift Bail Allows the entire wire feeder to be hung from A a crane or hook Order K1555 1 Power Feed F 10 only r Gas Guard Regulator For CO and Argon blend gases Reduces surge caused by excess pressure in supply hose Includes adjustable flow regulator with remov able adjustor key Used with standard regulator Kit provides for one gun Order K659 1 Dual Procedure Switch Allows the use of two welding proce dures with one Lincoln Magnum gun 15 ft 7 6m Must be used with optional Dual Procedure Panel or Dual Procedure with Memory Panel Order K683 3 K683 3 Feed Plate Incoming Bushing Connects directly to Magnum plastic conduit not included for use in boom systems long distances or large pay off packages For 025 1 16 wire Order K1546 1 For 1 16 1 8 wire Order K1546 2 K1 PN Undercarriage Includes mounting frame front cast ers rear wheels and handle for hand towing Order K163 Undercarriage Platform undercarriage for mounting two gas cylinders at rear of welder Order K1570 1 Wire Straightener For use with 10 Series wire drives or separat
9. itive locking problems heads allows for quick removal and e Gun receiver bushing provides low lt replacement for M e Two piece split wire guide construc cost adapters for Magnum or com tion provides easy access for e Feed head assembly can rotate to petitive guns along with easy inter inspection cleaning or changing to minimize gun cable kinks and changeability better mechanical different wire sizes bends Reduces gun stresses and support and reliable electrical improves feedability current transfer Drive rolls flip up for easy access Entire wire path is visible for easy access Changeable external gear for quick speed range change Removable outer wire guide for easy access to wire LINCOLN ELECTRIC FEED PLATE GUN RECEIVER BUSHINGS One of the following Gun Receiver Bushings is reguired for connecting gun and cable assemblies to the feed plate K1500 1 Gun Receiver K1500 2 Gun Receiver K1500 3 Gun Receiver K1500 4 Gun Receiver K489 7 Fast Mate Gun Bushing Optional Bushing Standard Bushing Optional Bushing Optional Receiver Bushing e Magnum 200 300 and 400 Magnum 200 and 400 fully Magnum 550 gun and cable e Magnum 200 300 and 400 Magnum gun and cable gun and cable assemblies assembled guns K497 2X assembly with K613 7 gun and cable assemblies assemblies with Fast Mate with K466 1 connector kit and K471 2X See below connection with K466 3 connector kit connectors Lincoln
10. minute or OFF Arc Control Inductance control adjusts arc characteristics to operators preference Burnback Time the arc stays on after the wire feed stops 0 1 to 0 25 seconds or OFF Post Flow Time the shielding gas flows after the weld stops 0 1 to 10 0 seconds or OFF Crater Fill Allows a second procedure used in the 4 step trigger mode Use for aluminum crater fill welding or a second procedure Order K1542 11 MSP2 PANEL This optional control panel has the complete setup selections of the MX panel This panel also adds synergic CV and pulse welding programs Required to use Wave Designer software Order K1542 12 NEW WIRE DRIVE ADVANTAGES e User can change external speed e Incoming bushings are available to range gear guickly Feeder can be accept guide bushings and conduits e Four gear driven rolls No tools low speed high torque or high often used with larger pay off wire needed to snap rolls on or off Each speed packages roll has two grooves of the same size to double feed life e Entire feed head can be removed e Simple wire drive roll pressure a for fast easy servicing Ideal for adjustment knob with indicator bar e Revolutionary Split Wire Guide production shops where downtime Roe precisely aligns and supports wire miste iminimized e Rugged electrically insulated door through the entire system protects drive system with simple Maximizes support and minimizes e Simple symmetric design of feed pos
11. ny combination of eguipment e Control cables can connect as extension cords up to 200 feet e Can be easily upgraded from simple to high capabilities e Flexible platform can be easily changed from bench to boom CV to Pulse etc e Spacious inverter design for easy service e 3 year warranty on parts and labor Manufactured under a guality system certified to ISO9002 requirements CONTROLS e All controls are located on the wire feeder to eliminate confusion e Control box is removable for bench or boom mounting e Two large displays and knobs for gloved hands e Presettable wire feed speed or amps and voltage or trim Actual values displayed while welding and for 5 seconds after welding has stopped e Capable of running from basic CV to high performance pulse programs e English or metric display e Control upgrades in less than 5 minutes WIRE FEEDER e Four driven rolls in a heavy duty drive system No tools needed for wire size changeover e Split wire guide for trouble free loading and feeding Perfect wire alignment and support e Powerful drive motor for large wires and high speeds in one model e Tachometer feedback for precise wire feeding e Wire reel stand holds 10 60 Ib wire packages on a 2 spindle Bench feeder mounts on power source Power Feed 10 may be used with or without optional swivel platform TECHNICAL SPECIFICATIONS POWER SOURCE Rated DC Outpu
12. or advice or information about their use of our products We respond to our customers based on the best information in our possession at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such information or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such informa tion 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 this type of fabrication methods and service requirements DISTRIBUTED BY LINCOLN ELECTRIC THE LINCOLN ELECTRIC COMPANY Local Sales and Service through Global Subsidiaries and Distributors Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com CC CV Welders E5 160 12 99
13. stored for recall Includes Dual Procedure Memories 2 6 may be accessed with an open air trigger pull using any welding gun Order K1542 9 DUAL PROCEDURE MEMORY Four welding procedures and processes may be stored for recall Includes Dual Procedure for each wire drive Gun 1 and 2 have 2 procedures each and each have access to 4 more from memory Order K1542 13 DUAL HEAD SELECT PANEL Allows control box K1539 2 to control two separate wire drives K1540 2 Comes standard with Power Feed 10 Dual Optional on Power Feed 10 Order K1542 14 OPTIONAL CONTROL PANELS PROCESS CONTROL PANELS POWER FEED 10 8 10 DUAL E WELD MOGE ABD CONTEC A cvs PCW RUM CORED 4 Lad A a CEMC GO jo s WELD C iT UP EMH F minae CVE COMI E BHH O a yi c cone r du HRACE TEIE u a Boe CRATER LLE T SET 3 4 AK TE SELECT M PANEL This optional control panel allows the user to select the type of output desired CV MIG CV Gas Shielded Flux Cored Outershield Metal Cored Flux Cored Innershield or CC Stick Soft Gouge The Arc Control varies inductance in the CV modes and arc force in the CC Stick mode Order K1542 6 MX2 PANEL This optional control panel adds CO Stick crisp mode and a flexible welding setup Shielding gas preflow 0 1 to 2 5 seconds or OFF Run in wire feed speed Adjustable for optimum start 75 to 150 inches per
14. t Input Amps at Rated DC Output Input Amps at Rated DC Output Amps at Rated DC Product Ordering Input AC Amps Volts 08 230 380 415 Output ra Dimensions Name Information Voltage Duty Cycle Pe ence are eos Range ra HxWxD Power K1517 5 208 230 460 60 Hz 5 570 26 x 20 x 33 in Wave 3 Phase 450 38 100 35 Amps 660 x 508 x 455 50 60 Hz 570 40 60 838 mm 50 Hz 400 38 100 500 43 60 254 Ibs 70 87 48 2 36 79 41 K1517 2 460 575 450 38 100 36 3 Phase 570 43 60 48 60 Hz 115 kg K1517 3 380 415 CE 400 36 100 5 520 256 lbs 3 Phase 500 40 60 Amps 116 kg 50 Hz WIRE FEEDER Wire Speed Wire Size Range Dimensions Ordering Range in 12000 HxWxD Power Feed 10 Information IPM m min Cored Giant in mm 62 Ibs 18 5 x 13 5 x 30 5 1 Low Speed Gear 023 3 32 035 1 8 28 1 kg 470 x 343 x 775 50 800 ipm 0 6 2 4 0 9 3 0 BOOM READY MODELS 1 2 20 3 m min 16 18 ft Generic High Speed Gear 023 1 16 035 5 64 Boom Package 75 1200 ipm 0 6 1 6 0 9 2 0 12 ft Zipline Ready Pkg 4 1 9 30 5 m min Both gears included 67 74 16 ft Zipline Ready Pkg 13x8 5x4 3 Control Box Only 9 i 330 x 216 x 102 7 6X12 9 x 13 7 3 Wire Drive Only 3 193 x 328 x 348 Fowor Foged 10 Dual Low Speed Gear 023 3 32 035 1 8 EN EE BENCH MODEL 50 800 ipm 0 6 2 4 0 9 3 0 106 Ibs 20 x 23 x 34 1 1 2 20 3 m min 48 kg 508 x 584 x An BOOM READY MODELS High Speed Gear
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