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Lincoln Electric IM916 User's Manual

1. DIAGRAMS P 1 F 1 L 6LEvVD 318V9 300419313 LNANI 1 quinu po2o 1u uudinb oun SNS juaueoe da e 10 juauedag esas 94 0 eu ode s weep au y sourd ay jo suo aulyoeul apisul pajsed s apos Jejnonied e 104 oyoeds oul siy Aq saulyoeul 104 90 you y EN OL SLNNOW m i wd YTY 01 SINNOW 08008 vs reg E M31038 gt ov 7 ov24 0333 G8V0834 10 INOD cuyos 3 4 195738 EECH vom eg Ween me als La ENYA 31001 TaNvd dOL aionzios CC NO LO3NNO9 SNISN3S 39V110A EEN ven DIE E CL s Std gt e gt gt gt gt gt SON SAM LNIYHNI 9d er ES gt gt HAOONS WAL 39V11OA ses quyos od gt Tz as gt e rem wna er SVL NNO easy use ON q31snuyis Vazsogden 3ound svo 0 JHON 82 11 3009 430333 JXIM 1VNQ WOL 43MOd NVYSVIC ONTAIM vos od Co tar wainonva CET OSOS te oss sva luo 9u 1 4 1 JO S WeIBeIP SIUL ALON ar rear tr arr er DEEN
2. Hi 220 200 LO 180 WELD WFS y WELD MODE START OPTIONS ARC CONTROL C END OPTIONS SET IR PORT SETUP The above example shows a wire mode constant cur rent weld modes would show Weld Amps rather than Weld WFS There are four items displayed on each Limit Setup screen The long alphanumeric display shows the selected attribute e g Weld WFS Volts etc The short alphanumeric displays show the selected attribute s high and low user limits The 7 segment displays show the value that is copied to procedure memory when a mem ory recall is performed Memory Value High Limi Low Limit D Hl 220 IRPORT 00 LO 180 SETUP WELD WFS WELD MODE O O START OPTIONS ARC CONTROL X END OPTIONS SET Attribute OPERATION B 25 One of these four items will blink to indicate which item will change when the Mode Select Panel Knob is rotated Initially the selected item will be the attribute To select the high limit press either Mode Select Panel button and the high limit value will begin to blink Pressing either Mode Select Panel button again will cause the memory value to blink pressing a third time will cause the low limit to blink Weld modes cannot be selected from the Limits Setup menu the mode must be selected and saved to memory prior to entering the Limits Setup menu The memory value high and low limit values are bound by the limits o
3. Improper gear box ratio configura tion Power Source calibration issues 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 10M DUAL WIRE FEEDER LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Tip seizes in diffuser Unit shuts off while welding or attempting to weld status light is red green alternating between colors every second Unit tries to recover after 30 seconds and may repeat again Drive roll does not turn although arc voltage is present and solenoid is on Feed head and Control Box sta tus LEDs are both solid green No wire feed solenoid or arc volt age Status LEDs are solid green No control of wire feed All status lights are solid green Preset WFS is adjustable on Control Box Wire feed motor turns and solenoid operates but no arc voltage is pre sent Status light is solid green on Control Box 1 Tip overheating due to prolonged or excessive high current and or duty cycle welding Note A light application of high tem perature antiseize lubricant such as Lincoln E2067 Graphite Grease may be applied to tip of threads Wire feed shut down circuit maybe electrically open Leads 570 and 572 in wire feed head The wire d
4. WFS The left display shows Wire Feed Speed while welding Display Options This setup parameter was previously named Display Energy If the previous software revision had this parameter set to display energy that selection will remain This option selects the information displayed on the alphanumeric displayes while welding Not all P 3 selections will be available on all machines In order for each selection to be included in the list the power source must support that feature A software update of the power source may be needed to include the features Standard Display The lower displays will continue to show preset information during and after a weld default Show Energy Energy is displayed along with time in HH MM SS format Show Weld Score The accumulative weld score result is shown Recall Memory with Trigger This option allows a memory to be recalled by quickly pulling and releasing the gun trigger To recall a memory quickly pull and release the trigger the number of times that correspond to the memory number For example to recall memory 3 quickly pull and release the trigger 3 times To recall memory 1 quickly pull and release the trigger the number of user memories plus 1 Memories cannot be recalled while the system is welding Disabled The gun trigger cannot be used to recall user memories default Enabled The gun trigger can be used to recall user memories POWER FEED 10M DUAL WIRE FEEDER
5. 15 41 POWER FEED 10M DUAL WIRE FEEDER LINCOLN 30 61 F 3 F 4 WIRE DRIVE DIMENSION PRINT DIAGRAMS ite o 10 Ms Del st r Y o UF Fr O gt E lt za 8 Oe e Er 5 1 N SE L Ti CO lt T o o AAA 4 25 TYP POWER FEED 10M DUAL WIRE FEEDER LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO ZS SE IR Chinese Donottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Notoque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension lsolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung lsolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e electro dos com a pele ou roupa molhada Isole se da peca e terra 888 950 8888 08865 1 98 97 5 5568 ATWSHRIELT FSU Keep flammable materials away Mantenga el material combustible fuera del rea de
6. Enable the voltage sense leads as follows TABLE A 2 Electrode Voltage Sensing 67 lead 67 lead required 67 lead required 67 lead required Voltage sense at studs Voltage sense at studs 67 lead required Voltage sense at studs POWER FEED 10M DUAL WIRE FEEDER LINCOLN Work Voltage Sensing 21 lead 21 lead optional 21 lead optional 21 lead optional Voltage sense at studs Voltage sense at studs 21 lead optional Voltage sense at studs The electrode voltage 67 sense lead is integral to the control cable to the wire feeder A 5 Work Voltage Sensing The standard Power Wave 455 s default to the work stud work sense lead disabled For processes requiring work voltage sensing con nect the 21 work voltage sense lead K940 from the Power Wave work sense lead receptacle to the work piece Attach the sense lead to the work piece as close to the weld as practical but not in the return cur rent path Enable the work voltage sensing in the Power Wave as follows A WARNING h e Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground e Always wear dry insulating gloves 1 Turn off power to the power source at the discon nect switch 2 Remove the front cover from the power source 3 The control board is on the left side of the power source Locate the 8 position DIP switch and look for switch 8 of t
7. HEAD 1 MEMORY HEAD 2 PROCEDURE PROCEDURE a B oe A GUN B ER PRESS AND HOLD TO SAVE Procedure A Procedure A 1 I Weld Parameters eat Weld Parameters Mode cd Mode i Preflow Post flow z Preflow Pos tflo w i Runin Memory 4 i Runin i Start Parameters 1 Start Parameters d Arc Control Arc Control i Crater Parameters mo Crater Parameters i Burnb ack r Burnback I Weld Parameters Procedure B Mons 1 ProcedureB 1 rocedure Preflow Postflow rocedure A d i Run in i i I weld Parameters 1 1 Weld Parameters roy L Mode Start Parameters Mode 1 i ie ror Arc Control 4 v Y ia y PRERA I Crater Parameters i ie aid Sch Y E Run in I S 25 Runin i Start Parameters rg LU 1 Start Parameters I f Ae e er Arc Control OS Arc Control d Crater Parameters I Crater Parameters Burnback J Burnback AAA A A ee eee D Es 4 Da ty 1 4 i BIO E POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 16 Each procedure contains stores the following informa tion Basic weld parameters as applicable WFS Volts Trim Amps Weld Mode Mode Number Preflow Postflow Time in Seconds Run in WFS Only work point determined by next active sequence state Start Parameters Status Slope Time WFS Volts Trim Amps Arc Control Setpo
8. auvO8 I d JO 301S ININOdWOD MIA 39N3N03S ALIAVO SLIHM M 3n18 n 038 H 8 Le913 Yad SIOEWAS 10 NOLLVWHOSN HOLIMS dO JAIS NO ILOANNOD NMOHS SSHOLIMS 319901 ON 13908 037 GV371 3LIHM HLIM SNOMV AGONY SN31 40 3903 LV14 3H1 LSSYVAN Nid O N YV39 033dS 0333 ALIHV10d 34vds EKOS UVAS 34vdsS EK 1 Vue oa 83114 we OK oa vid xaDW JOULAAW 1004 TNOLLdO A ae st vna Je manent sr moviasozu NNO dais ss snivis SE 3ouna svo MON men LHVH9 ONILL3S LS HOLIMS did EE 3SN3S e NOUD3NNOD SNISN3S SOVITON INPUT ELECTRODE CABLE 0 POWER FEED 10M DUAL WIRE FEEDER LINCOLN N LL 9968 N DIAGRAMS 80 F 2 SLOTS 310H433 t Bla Sev INldd NOISNAWIG 1 96 POWER FEED 10M DUAL WIRE FEEDER LINCOLN F 3 WIRE FEEDER BENCH MODEL DIMENSION PRINT DIAGRAMS 7 21 2000C L11044
9. 5 Position the Readi Reel so that it will rotate in a direction when feeding so as to be de reeled from bottom of the coil 6 Set one of the Readi Reel inside cage wires on the slot in the retaining spring tab 7 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 8 Slide cage all the way onto the adapter until the retaining spring pops up fully A CAUTION Check to be sure the Retaining Spring has fully returned to the locking position and has SECURELY locked the Readi Reel Cage in place Retaining Spring must rest on the cage not the welding elec trode 9 To remove Readi Reel from Adapter depress retaining spring tab with thumb while pulling the Readi Reel cage from the molded adapter with both hands Do not remove adapter from spindle POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 20 2 IN O D SPINDLE ADAPTER RETAINING SPRING RETAINING COLLAR GROOVES READI REEL INSIDE CAGE WIRES RELEASE BAR FIGURE B 1 To Mount 10 to 44 Lb 4 5 20 kg Spools 12 300 mm Diameter or 14Lb 6 Kg Innershield Coils The Spindle should be located in the LOWER mounting hole For 8 200 mm spools a K468 spindle adapter must first be slipped onto spindle For 13 14 Ib 6 Kg Innershield coils a K435 Coil Adapter must be used 1 Depress the Release Bar on the Retaining Collar and remove it from the spindle
10. A or B including its individual limits See the complete list above Memories can be accessed at anytime except when welding For wire fed processes this means anytime a trigger is NOT activated For CC processes it means anytime current is NOT flowing Saving to Memory To save an individual procedure A or B to memory first be sure the desired procedure of the desired feed head is active its LED is on Press and hold the button of the memory location you wish to store the procedure into After 2 seconds the LED above the memory button will begin to flash indicating that the procedure has been saved The LED will continue to flash as long as the memory button is depressed When released the memo ry LED will stay on steady and remain lit as long as the contents of the memory remain equal to the contents of the associated procedure If the memory button is released before the light begins to flash t lt 2s a memory recall function will occur instead of a save function i e the contents of the select ed memory will copied to the active procedure Note It is not required to load all 6 memories at once nor is it necessary to load them in order POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 17 Recalling from Memory To recall the contents of a memory into the active proce dure momentarily push the desired memory button for less than 2 seconds The saved parameters will be copied into the active procedure a
11. AND LIMITATIONS Connect a work lead of sufficient size and length Per Table A 1 between the proper output terminal on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact To avoid interference problems with other equipment and to achieve the best possible operation route all cables directly to the work or wire feeder Avoid excessive lengths and do not coil excess cable Minimum work and electrode cables sizes are as follows TABLE A 1 Current 60 Duty Cycle MINIMUM COPPER WORK CABLE SIZE AWG Up To 100 Ft Length 30 m 2 0 67 mm2 3 0 85 mm2 3 0 85 mm2 400 Amps 500 Amps 600 Amps NOTE K1796 coaxial welding cable is recommended to reduce the cable inductance in long distance Pulse applications up to 300 amps When using an inverter type power source like the PowerWaves use the largest welding electrode and work cables that are practical At least 2 0 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 Output connections on some Power Waves are made via 1 2 13 threaded output studs located beneath the spring loaded output cover at the bottom of the case front Most welding applications run with the electrode being positive For those appl
12. LINCOLN C 2 ACCESSORIES FIELD INSTALLED OPTIONS ACCESSORIES e OPTIONAL CONTROL PANEL KITS Arclink Cables Without Weld Cable Cable Lengths 8 ft K1543 8 16 ft K1543 16 25 ft K1543 25 50 ft K1543 50 100 ft K1543 100 e Co Axial Power Cable Cable Length 25 ft 350 amps K1796 25 50 ft 350 amps K1796 50 75 ft 325 amps K1796 75 100 ft 325 amps K1796 100 e Weld Power Cables Lug to Lug 3 0 600A 60 Duty Cycle 10 ft K1842 1 Lug to Lug 3 0 600A 60 Duty Cycle 35 ft K1842 35 Lug to Lug 3 0 600A 60 Duty Cycle 60 ft K1842 60 Lug to Lug 3 0 600A 60 Duty Cycle 110 ft K1842 110 Feed Plate Gun Receiver Bushings For use with Lincoln Gun Connector K466 1 Innershield SubArc Guns K1500 1 Tweco 4 Gun Connector K466 2 K466 10 Magnum 200 300 400 Guns K1500 2 Tweco 5 Gun Connector K1637 7 Magnum 550 Guns K1500 3 Miller Adapted Gun K466 3 K1500 4 OXO Gun K1500 5 Fast Mate Guns K489 9 Magnum 200 300 400 to K1500 2 Adapter K466 2 K613 7 Magnum 550 to K1500 3 Adapter K613 7 Incoming Bushings Lincoln Conduit 025 1 16 K1546 1 Lincoln Conduit 1 16 1 8 K1546 2 e Wire Straightener For 10 Series Feed Heads or Separate Mounting K1733 1 Spindle Adapters For Mounting Readi Reels and 2 D Spools up to 60 Ibs K162 1 For Mounting Readi Reels and 2 D Spools up to 60 Ibs For 14 Ib Innershield Coils to be mounted on 2 O D Sp
13. The left pushbutton Item 7 is used to toggle between Weld Mode selection and any active Arc Controls a k a wave controls The choices of wave controls varies by weld mode For example weld mode 31 has one wave control Pinch Weld mode 110 has three wave controls Peak Current Background Current and Tailout If the selected weld mode has no wave controls pressing the left pushbutton will have no effect If the selected weld mode uses one or more wave controls pressing the left pushbutton will sequence the selection from weld mode gt wave con trol 1 if active gt wave control 2 if active gt wave control 3 if active gt wave control 4 if active then back to weld mode The right pushbutton Item 9 is used to select attribut es that affect the available weld parameters such as preflow time burnback time etc Since most users will require infrequent access to these attributes they are separate from weld mode selection and wave control adjustment LAYOUT DIGITAL DISPLAY The MSP4 display consists of a large 4 digit 7 seg ment LED display two 8 character alphanumeric LED displays and one 16 character alphanumeric LED dis play The information shown on the various displays depends on the state of the user interface as described below When the MSP4 is being used to select a weld mode the 4 digit display Item 2 indicates the selected weld mode number The upper 8 character alphanu
14. backlashing of the coil which may tangle the wire A tangled coil will not feed so it must either be untangled or discarded 5 Be sure the coil reel is engaged with the spindle brake pin and the Release Bar on the Retaining Collar pops up and that the collar retainers fully engage the retaining groove on the spindle FIGURE B 2 SPINNER NUT CARDBOARD COIL LINER TIE WIRE SPRING LOADED ARM REEL POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 21 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 2 Insert the free end through the incoming guide tube Press the Cold Inch key or the Cold Feed Mode gun trigger and push the electrode into the drive roll WARNING When feeding with the gun trigger unless COLD FEED trigger mode is selected the electrode and drive mechanism are always HOT to work and ground and could remain HOT several seconds after the gun trigger is released 5 Feed the electrode through the gun 6 Adjust the brake tension with the thumbscrew on the spindle hub until the reel turns freely but with little or no overr
15. settings Integral TrigProc When using a Magnum DS dual schedule gun or similar that incorpo rates a procedure switch in the gun trigger mechanism While welding in 2 step machine operation is identical to the External Switch selection When welding in 4 step additional logic prevents procedure A from being re selected when the trigger is released at step 2 of the 4 step weld sequence The machine will always operate in 2 step if a weld is made exclusive ly in procedure A regardless of the 2 4 step switch position this is intended to simplify tack welding when using a dual schedule gun in 4 step Stall Factor Adjustment This option allows the adjustment of the stall factor in Push Pull operation The stall factor con trols the stall torque of the push motor when using a push pull gun The wire feeder is factory set to not stall unless there is a large resistance to feeding wire The stall factor can be reduced to stall more easily and possibly prevent bird nesting However low stall factors can cause motor stalling during normal welding conditions which results in the wire burning back to the tip or rapid tack welds If you are experiencing bird nests check for other feeding problems before adjusting the stall factor The default value for the stall factor is 75 with a range of 5 to 100 POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 10 OPERATION B 10 USER DEFINED PARAMETERS P 7 Gun Offset Adjustment This option adj
16. GTAW modes when equipped with a foot or hand amptrol the left encoder sets the maximum welding current Full depression of a foot or hand amptrol results in the preset level of current e In CC Stick and CC GTAW the right encoder acti vates and de activates the output Turning the encoder clockwise enables the output To de ener gize the output turn the encoder counter clockwise The display above will indicate the ON or OFF status of the output 4 DUAL PROCEDURE DUAL HEAD SELECT W MEMORY PANEL See Mode Select Panel Section for a Functional Description and detailed explanation This panel is intended for dual head applications and is essentially the same as the Dual Procedure with Memory panel except for the addition of a second pro cedure select push button It contains two procedure select buttons one for each head and six memory storage buttons In general terms dual procedure and memory are essentially independent storage locations for informa tion 5 MODE SELECT PANEL 4 MSP4 OVERVIEW The MSP4 is the standard mode select panel for the Power Feed 10M Dual Wire Feeder wire feeders The MSP4 is capable of Weld mode selection Arc Control adjustment Weld sequence control Preflow Time Run in WFS etc OPERATION FIGURE B 3 ALUMINU 3 64 PULSE 4043 Ar IR PORT SETUP WELD MODE C ARC SE O START OPTIONS C END OPTIONS DESC
17. 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 1 SAFETY 1 PRECAUTIONS DE SURETE 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 Sdret 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 a 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 cable 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 tou
18. Spot Timer Crater Time Burnback Time and Postflow Time The attributes that appear in the START and END OPTIONS are weld mode dependent For example if a TIG weld mode is selected Run in WFS will not appear since it is not relevant to the selected process Repeated pressing of the right MSP4 pushbutton will cycle through all relevant START and END OPTIONS Turning the MSP4 encoder will change the value of the selected option When the Start Time attribute is set to a value other than OFF the START OPTIONS LED will blink synchronous with the WFS and VOLTS TRIM LED s on the dual dis play panel This blinking is used to indicate that start wire feed speed and voltage trim can now be set to values dif ferent from those used while welding OPERATION B 6 Similarly if the Crater Time attribute is set to a value other than OFF the END OPTIONS LED will blink syn chronously with the dual display LED s indicating that crater wire feed speed and voltage trim now can be set to values different from those used while welding INFRARED IR CONTROL The MSP4 interface includes an infrared transceiver This allows wireless machine configuration using a Palm OS based hand held computer A proprietary Palm OS application ALPalm was developed for this purpose Contact Lincoln Electric for more information on this fea ture LOCKOUT SECURITY The MSP4 can be optionally configured to prevent the welder from changing selected MSP4 opt
19. WELDING ABBREVIATIONS WFS e Wire Feed Speed cc e Constant Current CV e Constant Voltage GMAW MIG e Gas Metal Arc welding GMAW P MIG Gas Metal Arc welding Pulse GMAW PP MIG Gas Metal Arc welding Pulse on Pulse GTAW TIG Gas Tungsten Arc welding SMAW STICK Shielded Metal Arc welding FCAW e Flux Core Arc Welding POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 2 OPERATION B 2 PRODUCT DESCRIPTION The Power Feed 10M Dual Wire Feeder unit con sists of a user interface and two wire drives This unit will be available as a bench model or a boom model The Power Feed 10M Dual Wire Feeder is a high performance digitally controlled modular wire feeder Properly equipped it can support the GMAW GMAW P FCAW SMAW GTAW and STT processes The Power Feed 10M Dual Wire Feeder is designed to be a part of a modular multi process welding system The Power Feed 10M Dual Wire Feeder is a Semi Automatic unit that is designed to interface with the Power Wave M family of welding machines It consists of a user interface Ul and wire drive WD that oper ate on 40VDC input power The user interface is designed to act as a means to access the functionality weld mode run in volts current etc of the welding system The wire drive unit is a 4 driven roll feeder that can push various types of welding wire Each component in the system has special circuitry to talk with the other
20. be mounted on 2 51 mm O D spindles K363P READI REEL ADAPTER Adapts Lincoln Readi Reel coils of electrode 30 lb 14 kg and 22 Ib 10 kg to a 2 51 mm spindle Durable molded plastic one piece construction Designed for easy loading adapter remains on spin dle for quick changeover K438 READI REEL ADAPTER Adapts Lincoln Readi Reel coils of electrode 50 60 lb 22 7 27 2 kg to a 2 51 mm spindle GUNS AND GUN ADAPTERS The Power Feed 10 Dual wire feeder is equipped with a factory installed K1500 2 gun connection Kit This kit is for guns having a Tweco 2 4 connector The Power Feed 10 Dual has been designed to make con necting a variety of guns easy and inexpensive with the K1500 series of gun connection kits Gun trigger and dual procedure lead connections connect to the single 5 pin receptacle on the front of the wire drive box MAGNUM 200 300 400 GUNS The easiest and least expensive way to use Magnum 200 300 400 guns with the Power Feed 10 Dual wire feeder is to order them with the K466 10 connector kit or to buy a completely assembled Magnum gun hav ing the K466 10 connector such as the K471 21 22 and 23 dedicated Magnum 400 guns and the K497 20 and 21 dedicated Magnum 200 guns MAGNUM 550 GUNS The easiest and least expensive way to use the Magnum 550 guns with Power Feed 10 Dual wire feeders is to order the gun with the K613 2 connector kit and install a K1500 3 gun connection kit
21. dip switch or by software configuration tool Dip switch configuration is as follows Refer to DIP switch settings of figures below Notes 1 Basic Power Feed 10M systems consist of one User Interface UI and up to two wire drives a dual head wire drive counts as two POWER FEED 10M DUAL BENCH DIP SWITCH SETTINGS ol 23 UI WD PCB S25629 c TPP SM located on Wire Drive divider panel d WD only PCB 525616 012345678 located on Wire Drive rear access door 00080588 CONTROLS Refer to Figure B 2 1 WIRE FEED SPEED WFS AMP METER This meter displays either the WFS or current value depending on the status of the machine Located below the display are the text WFS and Amps An LED light is illuminated next to one of these in order to indicate the units of the value displayed in the meter Prior to CV operation the meter displays the desired pre set WFS value Prior to CC Stick and CC GTAW operation the meter displays the preset current value During Welding the meter displays actual average amps but may be configured to display actual WFS After welding the meter holds the actual current or WFS value for 5 seconds During this time the display is blink ing to indicate that the machine is in the Hold period Output adjustment while in the Hold period results in the prior to operation characteristics stated above After the 5 second Hold period the meter displays the s
22. intended to cover all guns a Check that the drive rolls and guide tubes are proper for the electrode size and type being used If not change them b Lay the cable out straight Insert the connector on the welding conductor cable into the brass conductor block on the front of the wire drive head Make sure it is all the way in and tighten the hand clamp Keep this connection clean and bright Connect the trigger control cable polarized plug into the mating 5 cavity receptacle on the front of the wire drive unit INSTALLATION A 8 Note for Fast Mate and European connector style guns connect gun to gun connector making sure all pins and gas tube line up with appropri ate holes in connector Tighten gun by turning large nut on gun clockwise c For GMA Gun Cables with separate gas fittings connect the 3 16 I D gas hose from the wire drive unit to the gun cable barbed fitting d For water cooled guns see WATER CONNEC TIONS in this section GMAW SHIELDING GAS WARNING CYLINDER may explode if damaged e Keep cylinder upright and chained to 5 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 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 Me in use SEE AMERICAN NATIONAL ST
23. listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column 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 A 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 e Only qualified personnel should perform these trouble shooting procedures Observe all additional Safety Guidelines detailed throughout
24. not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 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 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 va
25. pulled and held Crater sequence begins Work point WFS move to set value in Crater sequence in the amount of time set within Crater sequence 7 Work point WFS Crater values held until trigger is released 8 Trigger released Burnback sequence begins and runs until Burnback timer expires 9 Postflow sequence begins and runs until Postflow timer expires 10 End of sequence ao o O1 OPERATION WFS vs Work point Output Waveform solid line represents WFS dashed line represents work point or machine output Additional Comments To achieve a Hot Start routine the values in step 2 Run In and Strike can be set such that work point output is set to a desired level while the Weld work point level will be set to a normal or nominal level for the particular process Example Strike Value 350A Strike Time 0 1 sec Weld Value 170A When the process is initiated the work point will jump to Strike work point of 350A with the set Run In WFS When the trigger is released the work point will jump to 170A in the 0 1 seconds and the Weld sequence will begin travers ing through the rest of the sequence using the functions set forth COLD FEED GAS PURGE SWITCH The Wire Drive has a Cold Feed Gas Purge Switch located near the gun connector This is an up down center off momentary toggle switch When held in the up position the Wire Drive will feed wire but neither the power source nor the gas so
26. refer to the What to Do column for the given Err PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION Capacitor A under voltage Excess voltage on the main capaci Left side facing machine tors May be caused by improper input configuration When accompanied by an undervolt age error on the same side it indi cates no capacitor voltage present on that side and is usually the result Capacitor B under voltage of an open or short in the primary Right side facing machine side of the machine Thermal error Indicates over temperature Usually accompanied by Thermal LED Check fan operation Be sure process does not exceed duty cycle limit of the machine Softstart error Capacitor precharge failed Usually accompanied by codes 32 35 Secondary overcurrent error The secondary weld current limit has been exceeded When this occurs the machine output will phase back to 100 amps typically resulting in a condition referred to as noodle NOTE For the Power Wave 455 R the secondary limit is 570 amps for the standard stud and 325 amps for the STT stud and all single phase operation Capacitor delta error The maximum voltage difference between the main capacitors has been exceeded May be accompa nied by errors 32 35 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 techni
27. slots then tighten The upper location must be used for 50 60 Ib Readi Reels Spools and Coils For smaller coils 44lb 30lb 10lb etc the spindle can be placed in either the upper or lower location The goal is to make the wire path from the coil to the wire drive an entry into the incoming guide tube that is as straight as possible This will optimize wire feeding performance WATER CONNECTIONS WATER COOLED GUNS FOR If a water cooled gun is to be installed for use with the Power Feed 10 Dual a K590 6 Water connection kit can be installed for each gun requiring water cooling Contained in the kit are the water lines and quick con nect water line fittings that install in the wire feed head Follow the installation instructions included in the kit Water cooled guns can be damaged very quickly if they are used even momentarily without water flowing To protect the gun we recommended that a water flow sense kit be installed This will pre vent wire feeding if no water flow is present WIRE FEED SHUT DOWN CIRCUIT OPTIONAL This option is intended as a means of disabling weld ing in the event that the water flow for a water cooled gun is not present Water cooled guns can be quickly damaged if they are momentarily used without water flow This matter can be avoided when a Lincoln Flow Sensor Kit K1536 1 is applied to the wire feeder shutdown circuit The Flow Sensor Kit has two control leads that become ele
28. 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 performance DUAL HEAD UNIT Two Control PC boards one board supports user interface and wire drive functions and second board supports second wire drive functions RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Feed 10M Dual Wire Feeder can be set up in a number of configurations They are designed to be used for GMAW GMAW P FCAW and STT processes for a variety of materials including mild steel stainless steel and cored wires Other process es such as STT SMAW and GTAW can be controlled using the user interface portion of the unit See Accessories Section for Part numbers and connec tions RECOMMENDED EQUIPMENT The Power Feed 10M Dual Wire Feeder must be used with communication compatible welding equip ment That is the communication protocol that is used in the welding system must be capable of communi cating with the wire feeder This would be any power source that has the Arclink receptacle available and is operating with LincNet or Arclink software POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 3 OPERATION B 3 Ge FEATURES AND CONTROLS POWER FEED 10M SERIES SYSTEM CONFIGURA TION The specific system component function of the pc board will be configurable by
29. the welding power source 2 Remove the rear access panel on the wire drive 3 Locate DIP switches on BOTH Wire Drive Boards 4 Set DIP switch 7 on BOTH Wire Drive Boards to the desired polarity DIP Switch 7 Position Polarity ON Up negative polarity OFF Down positive polarity 5 Assemble the rear access panel to the wire drive 6 Restore power A 4 VOLTAGE SENSING The best arc performance occurs when the Power Waves have accurate data about the arc conditions Depending upon the process inductance within the electrode and work lead cables can influence the volt age apparent at the studs of the welder Voltage sense leads improve the accuracy of the arc condi tions and can have a dramatic effect on performance Sense Lead Kits K940 xx are available for this pur pose If the voltage sensing is enabled but the sense leads are missing improperly connected or if the electrode polarity switch is improperly configured extremely high welding outputs may occur The ELECTRODE sense lead 67 is built into the control cable and is automatically enabled for all semi automatic processes The WORK sense lead 21 connects to the Power Wave at the four pin connector located underneath the output stud cover By default the WORK voltage is monitored at the out put stud in the Power Wave 455 For more informa tion on the WORK sense lead 21 see Work Voltage Sensing in the following paragraph
30. to the wire feeder LINCOLN INNERSHIELD AND SUB ARC GUNS All of these guns can be connected to the Power Feed by using the K1500 1 Adapter Kit LINCOLN FUME EXTRACTION GUNS The K556 250XA and K566 400XA guns require that a K489 9 Fast Mate adapter kit be installed The K206 K289 and K309 require only the installa tion of a K1500 1 connector in the Power Feed wire feeder NON LINCOLN GUNS Most competitive guns can be connected to the Power Feed by using one of the K1500 series adapter kits GUN RECEIVER BUSHINGS AND ADAPTERS K489 9 DUAL SCHEDULE FAST MATE ADAPTER This adapter installs directly into the wire drive feed plate to provide for use of guns with Fast Mate or European style gun connections This K489 9 will handle both standard Fast Mate and Dual Schedule Fast Mate guns K1500 1 LINCOLN INNERSHIELD GUN STANDARD CONNECTION Use this kit to connect the following guns Guns hav ing a Lincoln standard innershield gun connector Magnum 200 300 400 with K466 1 connector kit and Magnum 550 guns with the K613 1 gun connection kit K1500 2 TWECO 2 4 TYPE CONNEC TION The K1500 2 gun adapter comes factory installed on the Power Feed 10 Dual wire feeder Use this adapter for guns that have a Tweco 2 4 connector Such guns include Magnum 200 300 400 guns with K466 2 connector kit and completely factory assembled Magnum guns that are factory equipped with the K466 2 connector such as the K
31. trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos RA PTUSDORMTOBRER MME 4 ESHA Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo e E ERUSHOREAELTE CARP f HSRMABR T fE3B PH RMR FRAIMFHRRAR e 9 DERGE st 968 c 8 ez 548 Ye AIX ole ex at 58 2 6 61 5 48511 58 8 RE au FS Bo ya qye e AAS ASAl ous US W e Gi pia Gea y _ Am d s Aa ALIN gl zap dis de de Lilly eat lu eae dra slay JANN gl es SS Lay Aa pal aal DS dus de Ye 6 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITG
32. 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 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving I Si y Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 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 lt Q 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 LINCOLN All welders should use the following procedures in order to minimi
33. 400 Guns The easiest and least expensive way to use Magnum 200 300 400 guns with the Power Feed 10 Dual Wire Feeder is to order them with the K466 10 con nector kit or to buy a completely assembled Magnum gun having the K466 10 connector such as the K497 21 dedicated Magnum 400 POWER FEED 10M DUAL WIRE FEEDER LINCOLN A 8 Magnum 550 Guns The easiest and least expensive way to use the Magnum 550 guns with Power Feed 10 Dual wire feeders is to order the gun with the K613 7 connector kit and install a K1500 3 gun connection kit to the wire feeder Lincoln Innershield and Sub Arc Guns All of these guns can be connected to the Power Feed 10 Dual Wire Feeder by using the K1500 1 Adapter Kit Lincoln Fume Extraction Guns The K556 250XA and K566 400XA guns require that a K489 10 Fast Mate adapter kit be installed Installation of this adapter also requires a K1500 1 gun connector kit The K206 K289 and K309 require only the installa tion of a K1500 1 connector in the Power Feed wire feeder Non Lincoln Guns Most competitive guns can be connected to the Power Feed 10 Dual Wire Feeder by using one of the K1500 series adapter kits See Gun Adapters in ACCESSORIES section GENERAL GUN CONNECTION GUIDELINES The instructions supplied with the gun and K1500 series gun adapter should be followed when installing and configuring a gun What follows are some gener al guidelines that are not
34. 471 21 22 and 23 dedicated Magnum 400 guns and the K497 20 and 21 Magnum 200 guns K1500 3 TWECO 5 CONNECTION For Magnum 550 gun with K613 2 Connection Kit and any other gun having a Tweco 5 connector POWER FEED 10M DUAL WIRE FEEDER LINCOLN C 4 K1500 4 MILLER CONNECTION For any gun having a newer style Miller connector Install gun adapters per the instructions shipped with it K1500 5 OXO CONNECTION For any gun having an OXO style connector Install gun adapters per the instructions shipped with it CONDUIT ADAPTERS K1546 2 ADAPTER for use with Lincoln Magnum conduit and E Beam conduit wire sizes 1 16 120 For Magnum conduit Install the K1546 2 gun adapter at the incoming end of the feed plate secure with the set screw located at the back of the feed plate If a brass fitting is supplied with the conduit remove it from the feeder end of the conduit by unscrewing it Insert the conduit into the K1546 2 secure the conduit by fastening it the the adapter with the supplied knob screw For E Beam Conduit Install the K1546 2 gun adapter at the incoming end of the feed plate secure with the set screw located at the back of the feed plate Insert the conduit into the K1546 2 secure the conduit by fastening it the the adapter with the supplied knob screw DUAL PROCEDURE SWITCH OPTIONS K683 3 DUAL PROCEDURE SWITCH Kit includes gun switch and mountings for Lincoln Innershield a
35. ANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUBLISHED BY THE AMERICAN WELDING SOCIETY NOTE Gas supply pressure must be regulated to a maximum of 80 psi 5 5 bar Customer must provide a cylinder of shielding gas a pressure regulator a flow control valve and a hose from the flow valve to the gas inlet fitting of the wire drive unit Connect a supply hose from the gas cylinder flow valve outlet to the 5 8 18 female inert gas fitting on the back panel of the wire drive or if used on the inlet of the Gas Guard regulator See Below Gas Guard Regulator The Gas Guard Regulator is an optional accessory K659 1 on these models Install the 5 8 18 male outlet of the regulator to the 5 8 18 female gas inlet on the back panel of the wire drive Secure fitting with flow adjuster key at top Attach gas supply to 5 8 18 female inlet of regulator per instructions above POWER FEED 10M DUAL WIRE FEEDER LINCOLN A 9 WIRE SPINDLE PLACEMENT The reel stand provides two mounting locations for the 2 inch diameter wire reel spindle to accommodate var ious reel sizes Each mounting location consists of a tube in the center of the reel stand and locating slots on the outside of the reel stand The bolt used with a plain washer and lock washer slides through the tube from the side of the reel stand The bolt should be threaded into the wire spindle such that the tabs on the brake mechanism align with the locating
36. B 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 E Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle To Mount a 50 60 Lb 22 7 27 2 kg Coil Using K1504 1 Coil Reel For 50 60 Ib Readi Reels a K438 Readi Reel Adapter must be used The Spindle must be located in the UPPER mounting hole 1 With the K1504 1 Coil Reel mounted on to the 2 51 mm spindle or with reel laying flat on the floor loosen the spinner nut and remove the reel cover See Figure B 2 2 Before cutting the tie wires place the coil of elec trode on the reel so it unwinds from the bottom as the reel rotates OPERATION B 20 3 Tighten the spinner nut against the reel cover as much as possible by hand using the reel cover spokes for leverage DO NOT hammer on the spinner nut arms 4 Cut and remove only the tie wire holding the free end of the coil Hook the free end around the rim of the reel cover and secure it by wrapping it around Cut and remove the remaining tie wires A CAUTION Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls Failure to do this will result in
37. EBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion 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 Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventila o e exhaustao para remover fumo da zona respirat ria bsa ALMPSMEBTFLIICLT Feat W PH ESC THR U T Fu OTR E t ih ok cae o zero 7 e zyez Em AE MAS Ash 2124421214 552 8 HSHM iaee ce lan al su 6 ga Gall his Ja d igal Les A YA AA il Skill ze ARA ag y E geste Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servi o N o toque as partes el tricas nuas 2 2 lt lt PSR EMBA FE 78 24024 o HNE e 2PH AHS HAHAE File U il A eh Al JN all Do not operate with panel open or guards off No operar con panel abier
38. HTS 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 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 There may be too many components in the group All components in the group will be blinking green The power source bus may not be avail able The bus
39. LE EE Section D Safely D 1 Routine Maintenance iii D 1 Avoiding Wire Feeding ProblernSs J u me irc ie teens D 1 Periodic Maintenance sienne D 1 Procedure for Removing Feedplate from Wire Feeder A D 1 Troubleshooting LLL UI Aa Section E Safely ee E 1 Troubleshooting Guide s a tio E 2 thru E 12 Diagrams eisernen aa EAEE Section F Wiring Power Feed 10 Dual Head F 1 Control Box Dimension Pimt sis F 2 Bench Model Dimension Pmt 7 F 3 Dual Wire Drive Dimension Print ss F 4 Paris WE CN P 550 Series A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS Power Feed 10M Dual Wire Feeder WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC TYPE LOW SPEED RATIO HIGH SPEED RATIO Wire Size Wire Size Speed Solid Cored Speed Solid Cored K2234 3 Bench Model 50 800 IPM 025 3 32 in 035 125 in 75 1200 IPM 025 1 16 in 035 5 64 in K2316 1 Boom Model 1 27 20 3 m m 0 6 2 4 mm 0 9 3 2 mm 2 0 30 m m 0 6 1 6 mm 0 9 2 0 mm O ROL BO A DA AND OMP D D D T D D D DA D D A Dimensions Height Width Depth Weight Operating Storage K2234 3 Wire Drive amp 19 9 19 9 30 6 90 Lbs 14 F to 140 F 40 F to 185 F Bench Reel Stand 506 mm 506 mm 777 mm 40 8 Kg 10 C to 40 C 40 C to 40 C Model Feeder WELDING CAPACITY RATING A Dimensions do not include wire reel POWER FEED 10M DUAL
40. LINCOLN B 9 OPERATION B 9 USER DEFINED PARAMETERS Procedure Change Method This option selects how remote procedure selection A B will be made The selected procedure can be changed locally at the user interface by pressing the A Gun B button The following methods can be used to remotely change the selected procedure Use an external switch wired to the procedure select input Quickly releasing and re pulling the gun trigger Using a dual schedule gun which incorporates a procedure select switch in the trigger mecha nism pulling the trigger more than half way changes the procedure from A to B The possible values for this parameter are External Switch Procedure selection may only be performed at the memory panel or an external switch e g K683 Quick Trigger The selected procedure can be changed remotely by releasing and re pulling the trigger quickly while welding This feature is disabled in 4 Step trigger mode The external procedure switch is disabled To operate Select GUN on the memory panel Start the weld by pulling the gun trigger The system will weld with procedure A settings While welding quickly release then pull the gun trigger once The system will switch to pro cedure B settings Repeat to switch back to procedure A settings The procedure can be changed as many times as needed during the weld Release the trigger to stop welding The system will automatically return to procedure A
41. Power Feed 10M Dual Wire Feeder Juy 2010 For use with Power Feed 10M Dual Wire Feeder Code 11378 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 operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful ISO 9001 OUR OPERATOR S MANUAL Designed and Manufactured Under a Quality Program Certified by Inc ABS Quality Eval to ISO 9001 Re 5 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 _ 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 YOU
42. RIPTION IR Infrared Port Weld Mode Number Weld Wire Type Wire Size Weld Mode Description Status LED Lights Weld Mode Arc Control Selection Pushbutton Weld Mode or Arc Control Selection Pushbutton Start and End Options Status LED Lights Start End Options Through the use of alphanumeric displays the MSP4 provides standard text messages designed to enhance the user s understanding of the machine s operation as well as provide advanced capabilities The panel provides Clear identification of the selected weld mode Identification of weld modes not listed on the preprinted weld mode list label Control of up to four wave controls arc controls e Weld mode specific wave control name display Peak Background Pinch etc Unit values are displayed Amps in min etc User friendly machine setup and configuration e Limit setting for restricting the operators range of control e Lockout to prevent unauthorized changes to machine configuration Additionally the MSP4 includes an infrared IR port for wireless communication and configuration using a Palm OS based hand held computer and a simplified control layout POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 5 OPERATION B 5 LAYOUT CONTROLS SEE FIGURE B 3 The MSP4 panel controls Items 7 and 9 set consist of an encoder knob Item 8 and two push buttons The encoder is primarily used to change the value of the selected attribute
43. RSELF 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 D d Ges 1 h To avoid scalding do not remove the 94 6 radiator pressure cap when the engine is powered equipment AN Mrs S 9 1 a Turn the engine off before troubleshooting and maintenance 2 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 a outdoors AR ELECTRIC AND SR MAGNETIC FIELDS 1 c Do not add the fuel near an open flame Se may be dangerous 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
44. Selection to aid in troubleshooting The configuration is displayed as a text string on the lower display whenever the output is enabled This parameter is not saved on a power cycle but will be reset to False POWER FEED 10M DUAL WIRE FEEDER LINCOLN OPERATION B 12 USER DEFINED PARAMETERS Show Test Modes Most power sources contain weld modes used for calibration and test purposes By default the machine does not include test weld modes in the list of weld modes that are available to the operator To manually select a test weld mode set this option to Yes When the power source is turned off and back on again the test modes will no longer appear in the mode list Test weld modes typically require the machine out put to be connected to a grid load and cannot be used for welding View Diagnostics Diagnostics are only used for servicing or troubleshooting the Power Wave system Select Yes to access the diagnostic options in the menu Additional parameters will now appear in the setup menu P 101 P 102 etc View Event Logs Used for viewing all the system event logs Press the Right Button to enter the option Rotate Control Knob to select the desired event log to read Press the Right Button again to enter the selected log Rotating the Control Knob will scroll through the event log displaying the log index number event code and some other data Press the Left Button to back out to select another log Press the Left Butt
45. Trim at the Power Feed 10M Dual Wire Feeder using the right control knob located on the upper case front panel The Wire Feed Speed WFS is set using the control knob on the Torch The left control knob on the Power Feed 10M Dual Wire Feeder is inactive The actual WFS being set at the torch is displayed on the Power Feed 10M Dual Wire Feeder All weld parameters normally available for the active weld mode are available during push pull operation Refer to the Operation Section of this manual POWER FEED 10M DUAL WIRE FEEDER LINCOLN D 1 MAINTENANCE D 1 MAINTENANCE Safety Precautions 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 maintenance work Observe all additional Safety Guidelines detailed throughout this manual ROUTINE MAINTENANCE Gun and Cable connection After feeding every coil of wire check tightness of gun connection to wire feed brass bushing Drive Rol
46. 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 2 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 1 LINCOLN material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them
47. WIRE FEEDER LINCOLN A 2 SAFETY PRECAUTION 9 ELECTRIC SHOCK can kill e 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 Always connect the Power Wave grounding lug located inside the reconnect input access door to a proper safety Earth ground ELECTRODE ROUTING The electrode supply may be either from reels Readi Reels spools or bulk packaged drums or reels Observe the following precautions a The electrode must be routed to the wire drive unit so that the bends in the wire are at a mini mum and also that the force required to pull the wire from the reel into the wire drive unit is kept at a minimum ge The electrode is hot when the gun trigger is pressed and must be insulated from the boom and structure c If more than one wire feed unit shares the same boom and are not sharing the some power source output stud their wire and reels must be insulated from each other as well as insulated from their mounting structure CONTROL CABLE CONTROL CABLE CONNECTIONS All system control cables are the same All control cables can be connected end to end to e
48. acement 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 44 WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life 4 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page JEE e E Section A Technical Specifications sens A 1 Safety e Le Electrode Routing Control Cables nennen a E qaq autaqa sinan qaa A Qhasa Sis Control Cable Connections si A 2 Control Ca
49. ble Specifications Availiable Cable Assemblies A 2 Output Cable Connections and Limitations A 3 Negative Electrode Polarily u u u ua ia A 3 Electrode Sense Polarity To Set The Electrode Sense Polarity Switch A 3 Voltage Sensing sienne A 4 Wire Drive Gear Ratio High or Low Speed AA A 5 Selecting the Proper Gear Ratio A 5 Changing the Wire Drive Ratio ss A 6 Ratio Change Procedure siens A 6 Gear Ratio R ecognitioria uu u A 6 Wire Feed Drive ee 7 Procedure to Install Drive Rolls and Wire Guides A 7 Gun and Cable Assemblies with Standard Connection A 7 Gun and Cable Assemblies with Fast Mate Connection a A 7 General Gun Connection Guidelimes cren A 8 GMAW 610 30 scsi iaa at A 8 Wire Spindle Placement sienne A 9 Water Connections For Water Cooled Guns A 9 Wire Feed Shut Down Circuit Optional A 9 Examples of Connecting an Arclink Power Wave System A 10 Operation cio Section B Safety Precautions B 1 Definition of Welding Modes iii pedia B 1 Common Welding Abbreviations U L a B 1 Product 26501 2 Recommended Processes and Equipment U U no nnnrn nn nnn nro B 2 B 3 Operation Featur
50. cal troubleshooting assistance before you proceed POWER FEED 10M DUAL WIRE FEEDER LINCOLN E 12 TROUBLESHOOTING E 12 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10675 and above ERROR CODES FOR THE POWER WAVE 455 The following is a list of possible error codes that the Power Feed 10M Dual Wire Feeder can output via the display on this user interface 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 _ Single phase error Indicates machine is running on sin gle phase input power Usually caused by the loss of the middle leg L2 Error codes that contain three or four digits are defined as fatal errors These codes generally indicate inter nal errors on the Power Source Control Board If cycling the input power on the machine does not clear the error try reloading the operating system If this fails replace the con trol board CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10M DUAL WIRE FEEDER LINCOLN
51. cher simultan ment les parties sous tension des porte lectrodes connect s a deux machines a souder parce que la tension entre les deux pinces peut tre le total de la tension a vide des deux machines Si on utilise la machine a 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 du corps PRECAUTIONS DE SURETE POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES A SOUDER A dong TRANSFORMATEUR ET soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la 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 c
52. ck timer expires 7 Postflow sequence begins and runs until postflow timer expires 8 End of process 1 2 3 Li Q lt WFS vs Work point Output Waveform solid line represents WFS dashed line represents Work point or Machine Output POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 18 4 Step Synergic Operation Without Start Crater Burnback functions active Waveform Functionality 1 Trigger is pulled and released Preflow sequence begins and runs until Preflow timer expires 2 Run In sequence begins and runs until Arc is estab lished 3 Arc established Weld sequence begins 4 Trigger pulled Weld sequence continues Note This can be done anytime between Step 3 and 5 5 Trigger released Postflow sequence begins and runs until Postflow timer expires 6 End of sequence 1 2 3 4 WFS vs Work point Waveform Solid line represents WFS dashed line represents Work point or Machine Output 4 Step Synergic Operation With Start Crater Burnback functions active Waveform Functionality Trigger is pulled and released Preflow sequence begins and runs until Preflow timer expires 2 Run In sequence begins and runs until Arc is established Arc established Work point moves to set value in Start sequence 4 Trigger released Step 4 to 5 is start time set in Start sequence to get to Weld sequence Weld sequence begins and runs until trigger is pulled Trigger
53. cored wire electrodes It significantly reduces any abrasion to the electrode wire where it enters the feed head This results in even smoother more trouble free operation ACCESSORIES K1733 1 WIRE STRAIGHTENER Install per the Instructions shipped with the Kit K2339 1 PUSH PULL KIT AND K2320 1 FOOT AMPTROL AMPHENOL The push pull kit provides direct connection of a Cobra Gold or Prince XL torch to the Power Feed 10M Dual Wire Feeder wire feeder The kit is intended for use with the following Cobra Max Python or Prince XL torches K2252 1 Air Cooled 15ft 4 5m K2252 2 Air Cooled 25ft 7 6m Python K2212 1 Water Cooled 15ft 4 5m K2211 2 Air Cooled 25ft 7 6m K2212 2 Water Cooled 25ft 7 6m K2211 3 Air Cooled 50ft 15 6m K2212 3 Water Cooled 50ft 15m Prince XL K1592 1 Water Cooled 15ft 4 5 K1592 2 Water Cooled 25ft 7 6 K1592 3 Water Cooled 50ft 15 6 CAUTION Remove all input power to the Power Feed 10M Dual Wire Feeder before installing the Connection Adapter Kit WARNING Refer to the Owner s Manual of the Torch for Amperage and Duty Cycle rating information The torch rating may not match the rating of the power source MAKING A WELD WITH THE PRINCE XL OR COBRA GOLD TORCH INSTALLED K2296 2 Air Cooled 25ft 7 6 e Set the idle roll pressure on the wire drive between an indicator reading of 0 2 A recommended start point is 1 5 Depending on the weld mode set the Voltage or
54. ctrically common when the water is flow ing When integrated with the wire feeder shut down circuit it forms a closed common circuit and enables welding In the event that water is not flowing the Flow Sensor circuit shut down circuit is electrically opened which disables any further operation INSTALLATION Flow Sensor Kit installation is as follows 1 Remove rear access door of the wire feeder case 2 Locate the shutdown circuit leads inside feeder case cavity refer to table A 4 Note The leads will be connected together with insulated pink quick disconnects 3 Disconnect pink quick connect tabs 25 inch tab terminals 4 Locate and remove plastic plug on rear of wire feeder case 5 Insert Flow Sensor leads through hole 6 Connect Flow Sensor leads with shutdown circuit leads 7 Replace rear access door TABLE AA PF 10M Shutdown Feeder Cavity Location Leads Facing rear of unit Feeder 1 Shutdown 570 570 A B Upper Right Corner Feeder 2 Shutdown 670 670A Upper Left Corner POWER FEED 10M DUAL WIRE FEEDER LINCOLN A 10 EXAMPLES OF CONNECTING AN ARCLINK POWER WAVE SYSTEM ArcLink Power Wave products may be configured in many different ways The flexible system allows multi ple wire feeders to be connected to the same power source The diagrams represent some of the common methods for connecting ArcLink Products Important Bench model wire feeders cannot be sepa rated into a se
55. d Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10M DUAL WIRE FEEDER LINCOLN TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual Variable or hunting arc Poor arc striking with sticking or blast offs weld porosity narrow and ropy looking bead or electrode stubbing into plate while welding Wrong size worn and or melted contact tip Replace if neces sary Improper Drive Tension Worn work cable or poor work connection Replace if neces sary Loose electrode or work cable connections Wrong polarity Make sure elec If all recommended possible areas of trode polarity is correct for process being used misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Gas nozzle extended beyond gun Field Service Facility tip or wire stickout too long while welding Poor gas shielding on processes requiring gas Check gas flow and mixture Improper procedures or tech niques See Gas Metal Arc Welding Guide GS 100 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
56. d but trigger closure in MIG or pulse modes does Cold feed switch does not activate the motor but trigger does in MIG or Pulse modes LEDs are solid green on both control board and feed head boards 1 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 feed switch held up across plug pins 3 and 4 of J1 Release the cold inch switch and note that there should be no conti nuity now If either of these fail the problem is either in the purge switch or harnessing If continuity O K replace feed head board If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to per
57. ection will not appear in the list if the power source does not support a gas solenoid Notes Preflow is not available while TIG welding Postflow is available the same postflow time will be used in MIG and TIG When machine output on off is controlled via the upper right knob gas flow will not start until the tungsten touches the work Gas flow will continue when the arc is broken until the Postflow time expires When machine out put on off is controlled via an arc start switch or foot Amptrol gas will begin flowing when the output is turned on and will continue flowing until the output is turned off and the Postflow time expires Crater Delay This option is used to skip the Crater sequence when making short tack welds If the trigger is released before the timer expires Crater will be bypassed and the weld will end If the trigger is released after the timer expires the Crater sequence will function normally if enabled Reset Consumable Weight Use this option to reset the initial weight of the consumable package Press the Right Button to reset the consumable weight This option will only appear with systems using Production Monitoring POWER FEED 10M DUAL WIRE FEEDER LINCOLN SH OPERATION B 11 USER DEFINED PARAMETERS Push Pull Gun Knob Behavior This option determines how the potentiometer on the Push Pull torch will behave Gun Pot Enabled The welding wire feed speed is always controlled by the potentiometer on t
58. ectric Company for further assistance Current Power Feed 10M models that will not self configure K2316 1 Power Feed 10M Dual Boom These configurations will require Dip Switches to be set See the power source instruction manual on how to disable self configuration POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 1 OPERATION B 1 SAFETY PRECAUTIONS Read entire Operation section before operating the Power Feed 10M Dual Wire Feeder WARNING ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Sc 0 e Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away e Do not weld on closed contain ers 4 ARC RAYS can burn eyes and skin e Wear eye ear and body protec tion Observe all safety information throughout this manual DEFINITIONS OF WELDING MODES NON SYNERGIC WELDING MODES A Non synergic welding mode requires all welding process variables to be set by the operator SYNERGIC WELDING MODES A Synergic welding mode offers the simplicity of single knob control The machine will select the cor rect voltage and amperage based on the wire feed speed WFS set by the operator COMMON
59. elding power source for pipe thawing LINCOLN 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 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 e 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 Pi 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
60. equence initiates until Arc is established 3 Arc established Weld sequence begins 4 Trigger released Arc extinguished Postflow sequence begins and runs until postflow timer expires End of sequence 2 3 4 40 u WFS vs Work point Waveform solid line represents WFS dashed line represents Work point or Machine Output OPERATION 2 Step Synergic Operation With Burnback function active Waveform Sequence 1 Trigger is pulled Preflow sequence begins and runs until preflow timer expires 2 Run In sequence initiates until Arc is established 3 Arc established Weld sequence begins 4 Trigger released Arc extinguished Burnback sequence begins and runs until burnback timer expires 5 Postflow sequence begins and runs until postflow timer expires 6 End of sequence 1 2 3 4 5 6 WFS vs Work point Output Waveform solid line represents WFS dashed line represents Work point or Machine Output 2 Step Synergic Operation With Start Crater Burnback functions active Waveform Sequence 1 Trigger is pulled Preflow sequence begins and runs until preflow timer expires 2 Run In sequence initiates until Arc is established 3 Arc established Start sequence begins and runs for the amount of time set 4 Weld sequence begins 5 Trigger released Crater sequence begins and runs until crater timer expires 6 Arc Extinguished Burnback sequence begins and runs until burnba
61. es and Controls Items 1 thru 5 B 3 1 Wire Feed Speed WFS Amp Meter Ak B 3 2 Volt Trim Meter iii B 3 3 Output Controls sicario manne esta re usai ein raie B 4 4 Dual Procedure Dual Head Select W Memory Panel B 4 5 Mode Select Panel 4 MSbPA AE B 4 Layout Controls thru Accessing Machine Set up Menu a B 6 Set Up Feature Menu ii B 7 thru B 14 Dual Head Dual Procedure with Memory B 15 B 16 2 ole py 4 Step Opera OM ainda B 17 B 18 Cold Feed Gas Purge Switch siennes B 18 MOLINO nu B 19 Foot Armnptrol u y aa dE A Aldi etes dede ane deed e B 19 Wire Drive PC board adjustments im ce B 19 Wire Reel Loading sine B 19 B 20 Feeding Electrode and Brake Adjustment rr B 21 Drive Roll Pressure Setting sn B 21 Procedure for Setting Angle of Feedplate u a B 21 Gas Guard Regulator Settings B 21 MAKING Weld sssr eeaeee aea NOE o e AO 0 N a B 22 Wire Reel nck ngs e B 22 Wire Feed Overload Protection B 22 Component Stat s 1 B 23 Status Light State Secene eE a a E e E aE E a se B 23 B 24 0 B 25 El Section C Drive Roll and Guide Tube Kits C 1 Other Accessories n EEEE n nn rn nnnnnenannnnnnnnnnn anna C 2 thru C 5 vil TABLE OF CONTENTS vii 3 CT
62. et WFS CV modes or Amp CC modes value 2 VOLT TRIM METER This meter displays either the voltage or trim value depending on the status of the machine Located below the display are the text Volts and Trim An LED light is illuminated next to one of these in order to indicate the units of the value displayed in the meter CV Processes e Prior to CV GMAW and CV FCAW operation the meter displays the desired preset Voltage value Prior to CV GMAW P operation the meter displays the desired preset Trim value e During Welding the meter displays actual average volts After welding the meter holds the actual voltage value for 5 seconds During this time the display is blinking to indicate that the machine is in the Hold period Output adjustment while in the Hold period results in the prior to operation characteristics stat ed above After the 5 second Hold period the meter displays the set Voltage GMAW FCAW or Trim GMAW P value CC Processes The meter displays the status of the output e When output is enabled the meter will display ON e When there is no output the meter will display OFF FIGURE B 2 POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 4 3 OUTPUT CONTROLS The Power Feed 10M Dual Wire Feeder has 2 encoder knobs to adjust weld parameters e Each encoder changes the displayed value of the meter located directly above that encoder In CC
63. f the machine For example weld mode 49 may allow the wire feed speed to be adjusted between 10 and 200 in min These are referred to as machine limits Machine limits can vary between power sources and are also weld mode dependent The memory value must always be less than or equal to the high limit and greater than or equal to the low limit The high limit must always be greater than or equal to the low limit and the low limit must always be less than or equal to the high limit The rules are enforced auto matically If the low limit is increased above the memory value the memory value will automatically increase To lock an attribute to a specific value set the high and low limits to the desired value The user will not be able to change it After setting limits press the memory button that is flash ing The Mode Select Panel displays will prompt the user to save or discard the limit changes just made By pressing the Mode Select Panel button labeled YES changes to limits are saved and user limits are automati cally enabled By pressing NO any changes made to limits are dicarded and the limit enable disable state is not changed WAVEFORM CONTROL TECHNOLOGY Enable Limits No y WELD MODE C O START OPTIONS ARC CONTROL C G END OPTIONS SET To enable or disable limits that have been established for any memory press and hold the respective memory button in for more than 10 seconds until the Mode Select Panel d
64. form the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10M DUAL WIRE FEEDER LINCOLN E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual Displays and or indicator lights do 1 The encoders or switches may be not change when their correspond faulty ing switches and or knobs are acti vated to request a change Check for broken harness wire s or harness disconnected from intended location s and status lights are Power source is OFF Feeder supply or fuse circuit at power source is blown or tripped or defective harness or cabling Display or Control Board CB boards may be faulty Gun has not been selected at the Dual Procedure is not functioning control box Set dual procedure when using remote dual procedure switch on CB to gun Refer to switch Status lights are solid green operating instructions on CB and head boards If all recommended possible areas of Faulty remote dual procedure misadjustment have been checked switch Remove switch Check and the problem persists Contact continuity between switch pins your local Lincoln Authorized with switch open and closed If it Field Service Facility fails the continuity test repair or replace switch Faulty Local Dual procedure switch Wire feed speed is consistent and Dip switch on feed head board adj
65. g 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 fault Contact your Local Lincoln Field Service Facility Authorized Lincoln Field Service Facility Green LED ON System normal and functional System normal and functional and steady Normal Blinking LED Each illumination should exist for 0 5 seconds Fast Blinking LED Each illumination should exist for 0 1 seconds POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 25 LIMIT SETTING Each user memory can be optionally configured to limit the user s range of control over some user interface set tings By default user limits are not enabled To set lim its for a selected memory first select a weld mode and perform a memory save Next press and hold the mem ory button for five seconds Release the memory button when the memory LED begins to blink rapidly and the Mode Select Panel displays indicate Set Limits If the passcode has been set to a value other than zero the user will be prompted to enter it If the passcode is zero the Mode Select Panel will immediately display the Limit Setup menu and the SETUP LED will illuminate
66. he DIP switch 4 Using a pencil or other small object slide the switch right to the OFF posi tion if the work sense lead is NOT con nected Conversely slide the switch left gt to the ON position if the work sense lead is present 12 3 45 6 7 8 5 Replace the cover and screws The PC board will read the switch at power up and configure the work voltage sense lead appropriately Electrode Voltage Sensing Enabling or disabling electrode voltage sensing is automatically configured through software The 67 electrode sense lead is internal to the cable to the wire feeder and always connected when a wire feeder Poa Important The electrode polarity must be config ured at the feed head for all semi automatic processes Failure to do so may result in extreme ly high welding outputs INSTALLATION A 5 WIRE DRIVE GEAR RATIO HIGH OR LOW SPEED The speed range capability and drive torque of the Power Feed wire drives can be easily and quickly changed by changing the external drive gear The Power Feed Wire Feeders are shipped with both high speed and a low speed gears As shipped from the factory the low speed high torque gear is installed on the feeder If this is the desired gear ratio no changes need be made If a change in gear ratio is desired the systems needs to be made aware of which gear has been installed on the Wire Drive low or h
67. he push pull gun default The left front panel knob is only used to adjust Start and Crater wire feed speed Gun Pot Disabled The wire feed speed is always controlled by the left front panel knob This setting is useful when the operator wishes to have wire feed speed settings recalled from memories and not have the potentiometer overwrite the setting Gun Pot Proc A When in procedure A the welding wire feed speed is controlled by the potentiometer on the push pull gun When in procedure B the welding wire feed speed is controlled by the left front panel knob This setting allows a fixed wire feed speed to be selected in procedure changes Display Trim as Volts Option This option determines how trim is displayed False The trim is displayed in the format defined in the weld set default True All trim values are displayed as a voltage Arc Start Loss Error Time This option can be used to optionally shut off output if an arc is not established or is lost for a specified amount of time Error 269 will be displayed if the machine times out If the value is set to OFF machine output will not be turned off if an arc is not established nor will output be turned off if an arc is lost The trigger can be used to hot feed the wire default If a value is set the machine output will shut off if an arc is not established within the specified amount of time after the trigger is pulled or if the trigger remains pulled after an arc is lost Th
68. head or locally by momentarily depressing the procedure select push button of the inactive head When a procedure group feed head is active momen tarily depressing the procedure select pushbutton will change from A to Gun from Gun to B or from B to A The corresponding LED will be lit to let the user know which procedure is active When the Gun position is selected the Gun LED will be solid red and the active procedure LED A or B will be flashing The active procedure is determined by the dual proce dure Gun input located in the gun receptacle or through the Procedure Change with Trigger feature if properly configured OPERATION B 16 Note When in the Gun position if no dual procedure Gun switch is plugged in the Procedure defaults to A There are a total of four independent procedures avail able on this panel Two for each feed head Both the contents of the active procedure and the active procedure itself A to B or B to A can be changed on the fly during welding Changing the active status of the feed head can only be done when the system is in the idle state Procedure settings for each feed head and active procedure information are saved at power down Memory This feature allows the user to save and recall up to six individual procedures to from a secured storage location Each of the six memory locations is capable of storing a complete copy of the information associated with a single procedure
69. ications 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 Connect the other end of the electrode cable to the wire drive feed plate The electrode cable lug must be against the feed plate Be sure the con nection to the feed plate makes tight metal to metal electrical contact The electrode cable should be sized according to the specifications given in the work cable connections section Connect a work lead from the negative power source output stud to the work piece The work piece connection must be firm and secure especially if pulse welding is planned INSTALLATION A 3 For additional Safety information regarding the elec trode and work cable set up See the standard SAFE TY INFORMATION located in the front of the Instruction Manuals Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance NEGATIVE ELECTRODE POLARITY When negative electrode polarity is required such as in some Innershield applications reverse the output connections at the power source electrode cable to the negative stud and work cable to the positive stud ELECTRODE SENSE POLARITY This options allows for the setting of negative polarity sensing when a negative polarity welding process is performed When negative electrode polarity is re
70. igh speed This is accom plished through the selection of a dip switch on the wire drive PCB SELECTING THE PROPER GEAR RATIO See Technical Specifications at the front of the Installation Section for feed speed and wire size capa bilities with high and low speed gear ratios To deter mine whether you should be using the high or low speed ratio use the following guidelines e If you need to operate at wire feed speeds above 800 IPM 20 m m you will need to install the high speed gear large 30 tooth 1 6 inch diameter gear e If you do not need to run at wire feed speeds in excess of 800 IPM 20 m m you should use the low speed gear small 20 tooth 1 1 inch diameter gear Using the low speed ratio will provide the maximum available wire driving force Note If you are feeding only small diameter wires you may at your option install the high speed ratio POWER FEED 10M DUAL WIRE FEEDER LINCOLN A 6 CHANGING THE WIRE DRIVE GEAR RATIO Changing the ratio requires a gear and a dip switch setting change The Power Feed Wire Feeders are shipped with both high speed and a low speed gears As shipped from the factory the low speed high torque gear is installed on the feeder For identifica tion purposes the low speed high torque gear has 20 teeth and is 1 1 inches in diameter The high speed gear has 30 teeth and is 1 6 inches in diameter A WARNING Power down the Power Feed 10M Dual Wire Feeder by
71. int e Crater Parameters Status Slope Time WFS Volts Trim Amps Burnback Time in Seconds Limits All applicable limits DUAL HEAD DUAL PROCEDURE WITH MEMORY In general terms dual procedure and memory are essen tially independent storage locations for information Procedures can be thought of as temporary or working storage locations because they contain the weld settings readily available for use and when active are easily modified The dual procedure feature allows the operator to switch between procedures A and B on the fly while welding In addition to their procedure set up functions the procedure select push buttons serve as a means to manually select the active feed head wire drive Memory is more of a permanent storage location that cannot be accessed while welding It contains one com plete set of procedure information which can be recalled into the active procedure A or B Conversely the active procedure can be saved into memory for safe keeping Dual Procedure Head Select This feature allows the user to select Procedure A Gun Remote Select or Procedure B as well as selecting the active feed head wire drive The active feed head is indicated by the procedure group A Gun B with the illuminated LED s and only one procedure group feed head can be active at a time Changing the active feed head can be done in one of two ways Either remotely by pulling the trigger of the inactive feed
72. ions By default the welder will be able to change the weld mode all rele vant wave controls and all relevant start and end options LIMIT SETTING The MSP4 can be optionally configured to limit the operator s range of control of any weld parameter weld WFS arc control etc Limits are only available with the Dual Procedure Memory Panel MACHINE SETUP USER PREFERENCES The MSP4 can be used to configure and troubleshoot the machine ACCESSING THE MACHINE SETUP MENU To access the Machine Setup menu press both MSP4 push buttons simultaneously The MSP4 7 seg ment display will display the first user preference P O and the SETUP LED will illuminate e Pressing the left MSP4 pushbutton will exit the entire Machine Setup menu while in the P O user preference e Turning the MSP4 encoder knob will select other available User Preferences e To exit the User Preference Menu either rotate the MSP4 encoder until P O is displayed and press the left MSP4 pushbutton or press both MSP4 push but tons simultaneously at any time POWER FEED 10M DUAL WIRE FEEDER LINCOLN Rr OPERATION B 7 SET UP FEATURES MENU The Setup Menu gives access to the Setup Configuration Stored in the setup configuration are user parameters that generally only need to be set at installation The parameters are grouped as shown in the following table PARAMETER DEFINITION P 1 through P 99 Unsecured Parameters always adjustable P 100 thr
73. ircuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de karc Prot ger lautre 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 montan
74. ire drive Install Outer Wire Guide by sliding over locating pins and tightening in place Engage upper drive rolls if they are in the open position and close Pressure Door TO SET DRIVE ROLL PRESSURE see Drive Roll Pressure Setting in OPERATION GUN AND CABLE ASSEMBLIES WITH STANDARD CONNECTION The Power Feed 10 Dual Wire Feeder is equipped with a factory installed K1500 2 gun connection Kit This kit is for guns having a Tweco 2 4 connec tor The Power Feed 10 Dual Wire Feederl has been designed to make connecting a variety of guns easy and inexpensive with the K1500 series of gun connection kits Gun trigger and dual procedure lead connections connect to the single 5 pin receptacle on the front of the feed head box See Gun Adapters in ACCESSORIES section GUN AND CABLE ASSEMBLIES WITH FAST MATE CONNECTION including the Magnum 450 Water Cooled gun A K489 9 adapter will install directly into the wire drive feedplate to provide for use of guns with Fast Mate or European style gun connections This K489 9 will handle both standard Fast Mate and Dual Schedule Fast Mate guns Another way to connect a gun with a Fast Mate or European style gun connector to the Power Feed 10 Dual Wire Feeder is to use the K489 10 Fast Mate adapter kit Installation of this adapter also requires a K1500 1 gun connector See Gun Adapters in ACCESSORIES section Magnum 200 300
75. is is disabled while welding in Stick TIG or Gouge To prevent nuisance errors set Arc Start Loss Error Time to an appropriate value after considering all welding parameters run in wire feed speed weld wire feed speed electrical stick out etc To prevent subsequent changes to Arc Start Loss Error Time the setup menu should be locked out by setting Preference Lock Yes using the Power Wave Manager software Sense From Studs Use this option for diagnostic purposes only When power is cycled this option is automatically reset to False False Voltage sensing is automatically determined by the selected weld mode and other machine set tings default True Voltage sensing is forced to studs Sense Leads Selection Used in place of DIP switches for configuration of the work and electrode sense leads This option will only appear in the list if the power source has a hardware selection option 67 pos polarity An electrode sense lead is connected using positive polarity This is used by most GMAW welding procedures 67 neg polarity An electrode sense lead is connected using negative polarity This is used by most GTAW welding procedures and some Innershield procedures 67 amp 21 An electrode sense lead and work sense lead are connected Hardware Config The hardware determines the best remote sensing configuration This is applicable to MIG welding procedures only Voltage Sense Display Allows viewing of Voltage Sense Lead
76. isplays Enable Limits Pressing Yes will use the established limits while pressing No will ignore the established limits The limits that have been set for any memory location will not be erased if they are disabled IR PORT SETUP y Yes POWER FEED 10M DUAL WIRE FEEDER LINCOLN ACCESSORIES TABLE 0 1 DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4 Roll DH Drive 4 Driven Solid Steel Electrode 0 023 0 025 0 6 mm 0 030 0 8 mm 0 035 0 9 mm 0 040 1 0 mm 0 040 1 0 mm 0 045 1 2 mm 0 052 1 4 mm 1 16 1 6 mm 5 64 2 0 mm 3 32 2 4 mm Cored Electrode 0 030 0 8 mm 0 035 0 9 mm 0 040 1 0 mm 0 045 1 2 mm 0 052 1 4 mm 1 16 1 6 mm 0 068 1 7 mm 5 64 2 0 mm 3 32 2 4 mm 7 64 Lincore Hard Facing 2 8mm 7 64 2 8mm 120 3 0mm Aluminum Electrode 0 035 0 9 mm 0 040 1 0 mm 3 64 1 2 mm 1 16 1 6 mm 3 32 2 2 mm KP1505 5 KP1505 0305 KP1505 5 KP1505 0405 KP1505 5 KP1505 5 KP1505 0525 KP1505 1 16S KP1505 5 64 KP1505 3 32 KP1505 035C KP1505 035C KP1505 045C KP1505 045C KP1505 052C KP1505 1 16C KP1505 068 KP1505 5 64 KP1505 3 32 KP1505 7 64H KP1505 7 64 KP1505 120 KP1507 035A KP1507 040A KP1507 3 64A KP1507 1 16A KP1507 3 32A POWER FEED 10M DUAL WIRE FEEDER
77. ither 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 Jeither the group or feed head and feed head unique for all objects of the same equipment type A feed head has its feed head dip The appropriate feed head is 1 switches set to zero in a group with through 7 Check the dip switch set more than one object ting chart in INSTALLATION section and set the switches to make the Feed head ID non zero Did not receive a recognition com 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 section if not Also check continuity in the communication lines from CB to Power Source refer to wiring diagram Refer to Power source trouble shooting section for additional information If all these avenues fail replace CB mother PC board CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10M DUAL WIRE FEEDER LINCOLN E 8 TROUBLESHOOTING E 8 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10555 and below Note F
78. lays are turned back off The 16 character alphanumeric dis play will show Initializing while waiting for the Weld Sequencer to announce bus available The MSP4 alphanumeric displays will then display the name of the weld table loaded in the power source while the user interface prepares the machine for operation After all initialization is complete the MSP4 will dis play the weld mode information for the mode number that was selected when the machine was last pow ered down CHANGING WELD MODES To select a weld mode press the left MSP4 pushbut ton until the WELD MODE LED is illuminated Turn the MSP4 encoder until the desired weld mode num ber is displayed As the MSP4 encoder knob is rotat ed only the weld mode number is displayed After 1 second of encoder idle time the user interface will change to the selected weld mode and the new mode s electrode type electrode size and process information will appear WELD MODE SEARCHING The Weld Mode Search feature allows the selection of a welding mode based on certain criteria wire size process type etc SEARCHING FOR A WELD MODE To search for a mode turn the control knob until Weld Mode Search is displayed This will appear in between the highest and the lowest weld mode num bers POWER FEED 10M DUAL WIRE FEEDER LINCOLN D OD TD pn _ T m w pm ei 4 el TM B 6 Once Weld Mode Search is displayed pres
79. lenoid 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 weld ing 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 sole noid valve is energized but neither the power source nor the drive motor will be energized POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 19 HOT INCH Hot inch occurs when the trigger is pulled and an arc is not established After a 2 5 second period the Sequencer will jump to the Weld state and the wire feeder will run at the preset wire feed speed on the display The wire is hot output is on at this point Start Upslope Downslope Crater Burnback Postflow etc are all skipped when Hot Inch is activat ed FOOT AMPTROL A Foot Amptrol Kit can be installed in order to operate the output of the machine using a pedal Located on the Control Box the Right encoder turns output on off if desired The left encoder sets the max work point limit When the pedal is pressed OCV will be present and gas will not flow As soon as the tungsten touches the work and there is current flow the gas solenoid will turn on If the arc breaks the machine will enter the postflow state When the postflow timer expires the machine will return to OCV mode and no gas will flow until the arc is established If the
80. ls and Guide Tubes After feeding every coil of wire inspect the drive roll section Clean it as necessary The driver rolls and Inner Wire Guides are stamped with the wire sizes they will feed If a wire size other than that stamped on the roll s is to be used the roll s and Inner Wire Guides must be changed All drive rolls have two identical grooves The rolls may be flipped over to use the other groove See Procedure to Install Drive Rolls and Wire Guides in the INSTALLATION section for roll chang ing instructions Wire Reel Mounting Readi Reels and 10 through 30Ib 4 5 14kg Spools No routine maintenance required Avoiding Wire Feeding Problems Wire feeding problems can be avoided by observing the following gun handling and feeder set up proce dures a Do not kink or pull cable around sharp corners b Keep the electrode cable as straight as possible when welding or loading electrode through cable c Do not allow dolly wheels or trucks to run over cables d Keep cable clean by following maintenance instructions e Use only clean rust free electrode The Lincoln electrodes have proper surface lubrication f Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed g Do not use excessive wire spindle brake settings h Use proper drive rolls wire guides and drive roll pressure settings PERIODIC MAINTENANCE Every year inspect the gearbo
81. 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 the LED will bel 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 The feed head DIP switches may be set to zero The nodes with DIP switches set to zero will be blinking red The node bus may be off 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 10M DUAL WIRE FEEDER LINCOLN B 24 OPERATION B 24 STATUS LIGHT STATES CON T LED State Power Source LED LED on any other nodes components Wire Feeder Control Box Etc Red LED blinkin
82. meric display Item 3 indicates the electrode type steel aluminum etc The lower 8 character alphanumeric display Item 4 indicates the electrode size 035 1 16 etc The 16 character alphanumeric display Item 5 indi cates the process type and other information the exact content of which depends on the selected weld mode This additional information may include specific electrode type e g 4043 and or a description of the recommended gas e g HeArCO2 When the MSP4 is being used to change the value of an attribute the 7 segment displays show the select ed attribute s value The upper 8 character alphanu meric display is typically not used while changing an attribute s value The lower 8 character alphanumeric display is used to indicate the units of the selected attribute e g seconds in min etc The 16 character alphanumeric display is used to display the name of the selected attribute The content of the displays while the user interface is being used for advance machine configuration e g limit setting pass code entering machine setup etc is described in later sections POWER UP SEQUENCE When power is first applied to the machine a lamp test is performed All discrete LED s are turned on all 7 segment displays will show a pattern of 8 and all alphanumeric displays will show a hatch pattern where every other pixel is illuminated The lamp test will last for two seconds after which all disp
83. nd Magnum guns with 15 ft 4 5m con trol cable and 5 pin plug with two leads to connect to gun trigger Connect the 5 pin plug of the K683 3 Dual procedure Switch to the Power Feed 10 Dual Wire Feeder Trigger Dual Procedure 5 socket receptacle The two lead plug cord extending out of the 5 pin plug of the Dual Procedure switch is to be connected to the two trigger leads of the welding gun per instructions shipped with the kit ACCESSORIES K683 1 DUAL PROCEDURE SWITCH The K683 3 Dual Procedure Switch is the recom mended method of obtaining dual procedure for non Fast Mate guns but a K683 1 can be used For using a K683 1 with a fast mate gun see USING DUAL PROCEDURE WITH FAST MATE GUNS A K683 1 Dual Procedure Switch can be used on the Power Feed 10 Dual if a K686 2 adapter is used The K686 2 kit includes the gun switch and mountings for Lincoln Innershield and Magnum guns with 15 ft 4 5 m con trol cable and 3 pin plug K686 2 Adapter permits the 3 pin plug from the K683 1and 5 pin gun trigger plug to be connected to the 5 pin trigger dual procedure receptacle on the wire feeder USING DUAL SCHEDULE WITH FAST MATE GUNS ON 10 SERIES FEEDERS Configuration 1 K489 9 Dual Schedule Fast Mate adapter K575 Magnum 400 DS FM gun DS FM gun or competitive Configuration 2 K489 9 Dual Schedule Fast Mate adapter K683 1 Dual Procedure Switch 3 pin K686 2 Y adapter 3pin 5 pin to 5 pin Non DS Fast Mate g
84. nd the LED of the memory button will light indicating the source of the infor mation As with saving to memory this light will remain lit as long as the contents of the source memory remain equal to the contents of the associated procedure If a constant current mode is saved to memory with the power source in the on state the on status will be changed to off when the procedure is recalled This prevents a potential safety hazard if a memory button is pushed and the power source unexpectedly turns on 2 STEP 4 STEP OPERATION The Wire Drive has a 2 Step 4 Step switch located near the gun connector 2 Step Trigger Mode opera tion requires the operator hold the gun trigger closed in order to weld 4 Step Trigger Mode eliminates the need to hold the gun trigger closed while welding User selectable 4 step modes with or without current interlock The switch in the down position will enable 2 Step operation and in the up position enables 4 Step operation This switch has no effect in CC modes of operation such as stick welding Both 2 and 4 Step can be operated in Synergic and Non Synergic modes In a Synergic mode machine output tracks Wire Feed Speed WFS during welding In Non Synergic modes machine output is independent of WFS 2 Step Synergic Operation Without Start Crater Burnback functions active Waveform Sequence 1 Trigger is pulled Preflow sequence begins and runs until preflow timer expires 2 Run In s
85. nection in the communication leads or con trol cable Contact the Service Department for instructions on reloading the Welding Software Contact the Service Department for instructions on reloading the Welding Software Contact the Service Department for instructions on reloading the Welding Software Excessive Primary current present May be related to a switch board or output rectifier failure Low voltage on the main capacitors May be caused by improper input configuration When accompanied by an overvolt age error on the same side it indi cates no capacitor voltage present on that side and is usually the result of an open or short in the primary side of the machine 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 10M DUAL WIRE FEEDER LINCOLN E 11 TROUBLESHOOTING E 11 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10675 and above ERROR CODES FOR THE POWER WAVE 455 The following is a list of possible error codes that the Power Feed 10M Dual Wire Feeder can output via the display on this user interface 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
86. nents Kit specifications can be found in the ACCESSORIES section PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring When feeding without Power Feed 10 Dual Cold Feed feature electrode and drive mechanism are hot to work and ground and could remain energized several seconds after the gun trigger is released Turn OFF input power at welding power source before installation or changing drive roll and or guide tubes Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes Only qualified personnel should perform this installation Drive Roll Kit Installation KP1505 Turn OFF Welding Power Source e Pull open Pressure Door to expose rolls and wire guides e Remove Outer Wire Guide by turning knurled thumb screws counter clock wise to unscrew them from Feedplate Observe all additional Safety Guidelines detailed throughout this manual e Remove drive rolls if any are installed by pulling straight off shaft Remove inner guide INSTALLATION A 7 Insert inner Wire Guide groove side out over the two locating pins in the feedplate 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 w
87. ners 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 w
88. on again to exit this option View Fatal Logs Used for viewing all the system fatal logs Press the Right Button to enter the option Rotate Control Knob to select the desired fatal log to read Press the Right Button again to enter that log Rotating the Control Knob will scroll through the log displaying the log index number and fatal code Press the Left Button to back out to select another log Press the Left Button again to exit this option View Software Version Information Used for viewing the software versions for each board in the system Press the Right Button to enter the option Rotate Control Knob to select the desired board to read Press the Right Button again to read the firmware version Press the Left Button to back out to select another board Rotate the Control Knob to select another board or press the Left Button to exit this option View Hardware Version Information Used for viewing the hardware version for each board in the system Press the right MSP Button to enter the option Rotate Set knob to select the desired board to read Press the right button again to read the hardware version Press the left button to back out to select another board Press the left button again to exit this option View Welding Software Information Used for viewing the Weld Set in the Power Source Press the Right Button to read the Weld Set version Press the Left Button to back out and exit this option View Ethernet IP Address Used fo
89. ools K435 For 8 O D Small spools 10 12 5 lbs to be mounted on 2 O D spindles K468 K162 1H e Readi Reel Adapters Adapts 22 30 lb Readi Reels to a 2 Spindle K363P Adapts 50 60 Ib Readi Reels to a 2 Spindle K438 Coil Adapter Adapts 50 60 Ib Lincoln coils to a 2 Spindle K1504 1 Plastic Wire Cover for 30 44 Ib Wire Packages K1634 3 Plastic Wire Cover for up to 60 lb Wire Packages K1634 2 e Water Connection Kit K590 6 e Water Connection Adapter KP1529 1 Magnum Flow Sensor K1536 1 Gas Guard Regulator K659 1 e Dual Procedure Switch 5 pin with Trigger Leads K683 3 Large Panel Security Door K1574 1 Swivel Platform K1557 1 Light Duty Caster Kit K1556 1 Insulated Lift Bail K1555 1 K162 1 WIRE SPINDLE ADAPTER Spindle for boom mounting Readi Reels and 2 51 mm LD spools with up to 60 Ib 27 2 kg capacity User mounted to appropriately prepared boom frame work Includes an easily adjustable friction brake for control of overrun a 2 spindle is standard on Power Feed 10 Dual Bench model When a 2 51 mm spindle is used with Readi Reels or coils not on 12 805 mm or 8 203 mm O D spools an adapter is required K1504 1 COIL ADAPTER Permits 50 Ib to 60 Ib 22 7 27 2 Kg coils to be mounted on 2 51 mm O D spindles POWER FEED 10M DUAL WIRE FEEDER LINCOLN C 3 ACCESSORIES C 3 K435 COIL ADAPTER Permits 14 Ib 6 kg Innershield coils to
90. or 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 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 nat verify removing the noise source and pro gramming again lf 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 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
91. ough P 107 Diagnostic Parameters always read only SET UP FEATURES MENU See Figure B 3a 1 To access the set up menu press the Right and Left buttons of the MSP4 panel simultaneously Note that the set up menu cannot be accessed if the system is welding or if there is a fault The sta tus LED is not solid green Change the value of the blinking parameter by rotat ing the SET knob 2 After changing a parameter it is necessary to press the Right hand button to save the new setting Pressing the Left button will cancel the change 3 To exit the set up menu at any time press the Right and Left buttons of the MSP4 panel simulta neously Alternately 1 minute of inactivity will also exit the set up menu FIGURE B 3a SETUP MENU Mode Select Panel MSP4 LED Indicator Left Right button button SET Knob POWER FEED 10M DUAL WIRE FEEDER LINCOLN OPERATION B 8 USER DEFINED PARAMETERS Exit Setup Menu This setup menu parameter can be used to exit the setup menu When P 0 is displayed press the left Mode Select button to exit the setup menu Wire Feed Speed Units This option selects which units to use for displaying wire feed speed English inches minute wire feed speed units default Metric meters minute wire feed speed units Arc Display Mode This option selects what value will be shown on the upper left display while welding Amps The left display shows Amperage while welding default
92. parate control box and wire drive for a boom system Common ArcLink Systems The following Power Wave systems may all be assembled without any changes to the equipment DIP switches Basic Semi Automatic System Great for general fabrication Shown with K2230 2 Power Feed 10M Single Wire Feeder e K2203 1 Power Wave 455M STT Boom Semi Automatic System Often used when making large weldments Shown with K2314 1 Power Feed 10M Single Wire Feeder Boom includes wire drive and control box K2203 1 Power Wave 455M STT Robotic Semi Automatic System e Use the bench feeder for offline welding INSTALLATION A 10 Shown with K2230 2 Power Feed 10M Single Wire Feeder e K1780 2 PF 10 R e K2203 1 Power Wave 455M STT K2205 1 Wire Drive Module Hard Automation System Shown with e Control Box not available at the time of this writing e K1780 2 PF 10 R e K2203 1 Power Wave 455M STT K2205 1 Wire Drive Module Multiple Wire Feeder System e Load one feeder with solid wire the other with flux cored e Great for pipeline work Shown with K2429 1 ArcLink T Cable Connector e K2196 3 Power Feed 15M e K2203 1 Power Wave 455M STT ArcLink Systems Many other ArcLink systems may be assembled besides those shown in this manual The majority will self configure If an assembled system flashes the sta tus light green rapidly on all components contact the Lincoln El
93. pedal is released it turns the machine off postflow will be entered until time out When the postflow timer expires the machine will return to idle state and wait for trigger Preflow will be presettable for external trig gers if desired Triggering machine with encoder will skip preflow 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 boards 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 boards is used for this purpose See INSTALLATION section Wire Drive Ratio for information on how to set the DIP Switch OPERATION B 19 WIRE REEL LOADING READI REELS SPOOLS OR COILS To Mount a 30 Lb 14 kg Readi Reel Package Using the Molded Plastic K363 P Readi Reel Adapter The Spindle should be located in the LOWER mounting hole 1 Depress the Release Bar on the Retaining Collar and remove it from the spindle See Figure B 1 2 Place the Adapter on the spindle 3 Re install the Retaining Collar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle 4 Rotate the spindle and adapter so the retaining spring is at the 12 o clock position
94. pors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY D WELDING and CUTTING gt 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 contai
95. quired such as in some Innershield applications reverse the output connections at the power source electrode cable to the negative stud and work cable to the positive stud When operating with electrode polarity negative the Wire Feeder must be set to recognize this option To Set the Electrode Sense Polarity Switch e ELECTRIC SHOCK can kill Turn the input power OFF at the dis this equipment Do not touch electrically hot parts When changing the electrode polarity the weld cables must be changed at the power source 10M Dual must be properly set Operation with the DIP switch in the wrong position will cause erratic A WARNING connect switch before working on studs and the DIP switch inside the Power Feed arc performance POWER FEED 10M DUAL WIRE FEEDER LINCOLN A 4 INSTALLATION The Power Feed 10M Dual Wire Feeder is factory set for Electrode Positive welding Most welding procedures use Electrode Positive weld ing Some Innershield procedures may use Electrode Negative welding For most applications the Power Feed 10M Dual Wire Feeder will have both sides of the Wire Drive set to the same polarity To weld with opposite polarities each head would have to be weld ing on isolated work pieces and the weld cable attach ing the two feed heads would have to be removed To change the DIP switch inside the Power Feed 10M Dual Wire Feeder for electrode polarity 1 Turn off power at
96. r 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 Whenever you request repl
97. r viewing the IP address of Ethernet compatible equipment Press the Right Button to read the IP Address Press the Left Button to back out and exit this option The IP address can not be changed using this option View Power Source Protocol Used for viewing the type of power source the feeder is connected to Press the Right Button to identify the power source as either LincNet or ArcLink Press the Left Button to back out and exit this option POWER FEED 10M DUAL WIRE FEEDER LINCOLN OPERATION B 13 USER DEFINED PARAMETERS Encoder Lockout Locks one or both of the upper knobs encoders preventing the operator from changing wire feed speed amps volts or trim The function of each upper knob depends on the selected weld mode When a costant current weld mode is selected e g Stick TIG Gouge the upper right knob will always function as an on off switch This parameter can only be accessed using Power Wave Manager software Memory Change Lockout Determines if the memories can be overwritten with new contents No Memories can be saved and limits can be configured default Yes Memories cannot be changed saving is prohibited and limits cannot be re configured This parameter can only be accessed using Power Wave Manager software Memory Button Disable Disables the specified memory button s When a memory is disabled welding procedures cannot be restored from or saved to that memory If an attempt is made to sa
98. rive motor may be overloaded Check for mechani cal restrictions in the wire feeding path Check for loose or broken leads at the wire drive motor Defective wire feed motor or feed head Printed Circuit PC board Note With WFS set to max con trol board should supply 24 VDC to motor leads 550 551 Faulty gun trigger switch The gun trigger switch or circuit may be faulty Check or Replace Defective motor tach or control PC board or harness Check for loose or faulty connections on motor tach See Wiring Diagram Power source may be defective See Power Source LED Status Light Chart Check for broken Hi impedance connection in weld circuit If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10M DUAL WIRE FEEDER LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 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 activate solenoi
99. sing the right pushbutton labeled Begin will start the search process During the search process pressing the right pushbut ton typically acts as a next button and the left push button typically acts as a back button Rotate the control knob then press the right pushbut ton to select relevant welding details such as welding process wire type wire size etc When the final selection is made the PF10MTM will automatically change to the weld mode found by the Weld Mode Search process Earlier products may not have this feature To acti vate this feature a software update may be needed from www powerwavesoftware com CHANGING ARC WAVE CONTROL If the selected weld mode uses any of the four available wave controls users can press the left MSP4 pushbutton until the ARC CONTROL LED is illuminated The value name and units if applicable of the available wave con trols will appear Note that the name of the control is derived from the weld table and may not necessarily appear as Wave Control Repeated pressing of the left MSP4 pushbutton will cycle through all active wave con trols and then the weld mode Turning the MSP4 encoder will change the value of the displayed wave control CHANGING WELD SEQUENCE BEHAVIOR Weld sequencing attributes are grouped into two cate gories START OPTIONS and END OPTIONS START OPTIONS may include Preflow Time Run in Wire Feed Speed and Start Time END OPTIONS may include
100. t shaft with engine oil or equivalent Install gear onto output shaft and secure with flat washer lock washer and Phillips head screw which were previously removed 6 Tighten the screw on lower right face of feed plate 7 Re attach feed plate to wire feeder if removed in Step 2 8 Feed plate will be rotated out of position due to the gear change Adjust the angle of the feed plate per the instructions above 9 Set the wire drive gear ratio switch on Wire Drive PC board as follows GEAR RATIO RECOGNITION 1 Remove the rear access door from the wire feeder case 2 Locate the dip switch bank on the P C board refer to table A 3 3 Locate dip switch 8 and move it to the appropriate gear ratio setting as described below FIGURE A 2 swt UP High Speed Gear Ratio DOWN Low Speed Gear Ratio 4 Replace the rear access door of the wire feeder case Note The system recognizes dip switch settings only during system power up TABLE A 3 PF 10M Feeder location PF 10M PC board location Facing rear of unit Facing rear of unit Right On inside divider panel POWER FEED 10M DUAL WIRE FEEDER LINCOLN A 7 WIRE FEED DRIVE ROLL KITS NOTE The maximum rated solid and cored wire sizes and selected drive ratios are shown on the SPECIFICATIONS in the front of this section The electrode sizes that can be fed with each roll and guide tube are stenciled on each part Check the kit for proper compo
101. tely 75 19mm of the exten sion guide for cored wire 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 A WARNING When using an Open Arc z process it is necessary to use 4 correct eye head and body pro tection 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 OPERATION B 22 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 Po
102. tes LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you hank OU to take pride in operating this Lincoln Electric Company product zer as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particula
103. then replace the CB mother PC board Display shows any of the following 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 10M DUAL WIRE FEEDER LINCOLN E 9 TROUBLESHOOTING E 9 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10555 and below 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 replace CB mother PC board Microprocessor RAM Error in object Cycle power as in Err 211 If Err 212 board other than Control Box Such lis still displayed then replace the PC as feed head board in the object with the fault The object with the fault should be solid red on its status LED three dashes Appears on right display of 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 ou
104. this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER FEED 10M DUAL WIRE FEEDER LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual Rough wire feeding or wire not feed l1 Gun cable kinked and or twisted ing 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 con tact tip Replace if necessary 10 Incorrect drive roll pressure Readjust if necessary 11 Improper liner tip or inner outer guides Replace if necessary 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 Fiel
105. to o 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 Mantenha se afastado das partes moventes Nao opere com os paineis abertos ou guardas removidas e RIPI ERAL EE TRMEIMFELEVOEFEDN ORERTMNLARS ARK E e gdo Bel yqz SA HAR MEY COS 13 al Uu Jadi e Ale Viel Ga Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it ES BIR Chinese LEIA E COMPREENDA AS INSTRU OES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR FRR PBUH 2 058 4 gt 88 4900773 EL TRHORARE 1 6 B WAN 18 MRA fs 89 8832 44 FL ii PA 38 Sp R J OA B3 55 15 S o D AZo SSH 265 SAMI HAS Arar 2 55 EPS HHEH eal vele QU dl lacas ail y Was J Aal y las og ESA Kies lesa sl y candy LA LINCOLN e World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
106. tput to Power Source Turning the right encoder counter clockwise will deactivate output 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 10M DUAL WIRE FEEDER LINCOLN E 10 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10675 and above ERROR CODES FOR THE POWER WAVE 455 The following is a list of possible error codes that the Power Feed 10M Dual Wire Feeder can output via the display on this user interface 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 SYMPTOMS Display shows any of the following POSSIBLE CAUSE RS CAN communication bus off User Interface time out error Unprogrammed Weld Mode Empty Weld Table Weld Table checksum error Primary overcurrent error Capacitor A under voltage Left side facing machine Capacitor B under voltage Right side facing machine RECOMMENDED COURSE OF ACTION Probably due to excessive number of communication errors User Interface is no longer respond ing to the Power Source The most likely cause is a fault bad con
107. tup Menu Lock Determines if the setup parameters can be modified by the operator without entering a pass code No The operator can change any set menu parameter without first entering the passcode even if the passcode is non zero default Yes The operator must enter the passcode if the passcode is non zero in order to change any setup menu parameters This parameter can only be accessed using Power Wave Manager software POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 14 OPERATION B 14 USER DEFINED PARAMETERS Set User Interface Passcode Prevents unauthorized changes to the equipment The default passcode is zero which allows full access A nonzero passcode will prevent unauthorized changes to memory limits saving to memory if P 502 Yes changes to setup parameters if P 505 Yes This parameter can only be accessed using Power Wave Manager software UI Master Lockout Locks all user interface controls preventing the operator from making any changes This parameter can only be accessed using Power Wave Manager software POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 15 OPERATION B 15 FIGURE B 4 Head Procedure Select e Press to select head or change active Memo e Permanent storage for procedure procedure settings e Changes to weld settings affect e Six available memory locations One active procedure only procedure A or B can be stored in each
108. turning off its companion Power Wave power source For maximum safety disconnect the control cable from the Power Feed 10M Dual Wire Feeder GEAR RATIO CHANGE PROCEDURE 1 Pull open the Wire Drive Door 2 Remove the Phillips head screw retaining the pin ion gear to be changed and remove the gear If the gear is not easily accessible or difficult to remove remove the feed plate from the gearbox To remove feed plate a Loosen the clamping collar screw using a 3 16 Allen wrench The clamping collar screw is accessed from the bottom of the feed plate It is the screw which is perpendicular to the feeding direction b Loosen the retaining screw which is also accessed from bottom of feeder using a 3 16 Allen wrench Continue to loosen the screw until the feed plate can be easily pulled off of the wire feeder 3 Loosen but do not remove the screw on the lower right face of the feed plate with a 3 16 Allen wrench 4 Remove the screw on the left face of the feed plate If changing from high speed larger gear to low speed smaller gear line the lower hole on the left face of the feed plate with the threads on the clamping collar Line the upper hole with the threads to install larger gear for high speed feeder If feed plate does not rotate to allow holes to line up further loosen the screw on right face of feed plate INSTALLATION A 6 5 Remove the small gear from the output shaft Lightly cover the outpu
109. un Magnum 450WC Magnum 200 Magnum 300 Magnum 400 and others K590 6 WATER CONNECTION KIT Install per the instructions shipped with the kit K1536 1 WATER FLOW SENSOR KIT Install per the instructions shipped with the kit POWER FEED 10M DUAL WIRE FEEDER LINCOLN C 5 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 INSTALLA TION section K1556 1 LIGHT DUTY CASTER KIT This option provides 4 casters and all required hardware to mount it to the Power Feed Wire Feeder K1555 2 INSULATED LIFT HOOK For applications where an insulated lift hook is required This kit provides an easily installed heavy duty insulated lift eye that mounts to the wire reel stand mast See the instructions provided with the kit for installation K1546 1 CONDUIT ADAPTER Install per the Instructions shipped with the Kit K1551 2 INCOMING BUSHING 4 Ball Roller Standard on codes 10600 and up This ball bearing equipped incoming bushing can be used in place of the standard incoming wire bushing when feeding solid steel or
110. un when wire feeding is stopped Do not overtighten DRIVE ROLL PRESSURE SETTING The Power Feed 10 Dual Wire Feeder pressure is fac tory pre set to about position 2 as shown on the pressure indicator on the front of the feedplate door This is an approximate setting The optimum drive roll pressure varies with type of wire surface condition lubrication and hardness Too much pressure could cause 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 B 21 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 E If the wire birdnests jams or breaks at the drive roll the drive roll pressure is too great Back the pressure setting out one turn run new wire through gun and repeat above steps 2 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 one turn reconnect the gun tighten locking clamp and repeat the above steps PROCEDURE FOR SETTING ANGLE OF FEEDPLATE 1 Loosen the clamping collar screw using a 3 16 Allen wrench The clamping collar screw is accessed from the bottom of the feedplate It is the scre
111. ustable but operates at the does not match gear ratio used at wrong speed gear box If using a high speed gear the feed head PC board dip switch 8 must be set to 1 or ON Feed head board is not properly reading DIP switch Replace feed head PC board Status LED not solid green 1 see LED Status Light Chart Gas solenoid not operating properly 1 Inlet gas pressure exceeding 80 or intermittent psi 5 5 bar Verify that gas pres sure regulator is operating prop erly 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 10M DUAL WIRE FEEDER LINCOLN E 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455 Code 10555 and below Note For any Err 4 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 P aa s saw More than 1 CB with the same group Make sure the group dip switch set i 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 e
112. usts the wire feed speed calibration of the pull motor of a push pull gun This should only be performed when other possible corrections do not solve any push pull feeding problems An rpm meter is required to perform the pull gun motor offset calibration To perform the calibration procedure do the following Release the pressure arm on both the pull and push wire drives Set the wire feed speed to 200 ipm Remove wire from the pull wire drive Hold an rpm meter to the drive roll in the pull gun Pull the trigger on the push pull gun Measure the rpm of the pull motor The rpm should be between 115 and 125 rpm If neces sary decrease the calibration setting to slow the pull motor or increase the calibration set ting to speed up the motor The calibration range is 30 to 30 with O as the default value TIG Gas Control This option allows control over which gas solenoid actuates while TIG welding Valve manual No MIG solenoid will actuate while TIG welding gas flow is manually con trolled by an external valve Solenoid auto This selection only applicable to PWC300 The MIG solenoid will turn on and off automatically while TIG welding Feeder Solenoid No applicable to PWC300 The internal feeder MIG solenoid will turn on and off automatically while TIG welding Pwr Src Solenoid Not applicable to PWC300 Any gas solenoid connected to the power source will turn on and off automatically while TIG welding This sel
113. ve or restore a disabled memory a message will be displayed on the lower display indicating the memory number is disabled In multi head systems this parameter disables the same memory buttons on both feed heads This parameter can only be accessed using Power Wave Manager software Mode Select Panel Lock Selects between several Mode Select Panel lockout preferences When a Mode Select Panel selection is locked and an attempt is made to change that parameter a message will be displayed on the lower dis play indicating the parameter is locked All MSP Options Unlocked All adjustable parameters on the Mode Select Panel are unlocked All MSP Options Locked All knobs and buttons on the Mode Select Panel are locked Start amp End Options Locked The Start and End parameters on the Mode Select Panel are locked all others are unlocked Weld Mode Option Locked The weld mode cannot be changed from the Mode Select Panel all others Mode Select Panel settings are unlocked Wave Control Options Locked The Wave Control parameters on the Mode Select Panel are locked all others are unlocked Start End Wave Options Locked The Start End and Wave Control parameters on the Mode Select Panel are locked all others are unlocked Start End Mode Options Locked The Start End and Weld Mode Select parameters on the Mode Select Panel are locked all others are unlocked This parameter can only be accessed using Power Wave Manager software Se
114. w which is perpendicular to the feeding direction 2 Rotate feedplate to the desired angle and tighten clamping collar screw GAS GUARD REGULATOR SETTING 1 With the gas supply shut off the Gas Guard regu lator flow adjusting Key should be set to maximum full clockwise which is rated to be 60 SCFH 28 l min 2 Adjust gas supply flow rate for a level higher than will be required then adjust Gas Guard flow adjusting Key counterclockwise to the desired gas flow rate POWER FEED 10M DUAL WIRE FEEDER LINCOLN B 22 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 Set 2 step 4 step switch on wire drive to desired mode of operation Refer to 2 step 4 step switch operation in this section 5 Select Weld Mode Refer to Control Box Operation in this section 2 Use Control Select switches increment decrement switches and encoder knobs to set desired para meters for weld depending on what options are installed Refer to Control Box Operation in this section 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 approxima
115. wer Feed 10 Dual 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 The wire drive provides overload protection of the wire drive motor If the wire drive motor becomes over loaded 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 automati cally 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 10M DUAL WIRE FEEDER LINCOLN B 23 OPERATION B 23 COMPONENT STATUS LIG
116. x and coat the teeth with a Moly disulfide grease Do Not use graphite grease e Every six months check the motor brushes Replace them if they are less than 1 4 long e Replace the drive rolls and inner wire guide when they are worn e Replace the pig tail if the insulation is cut abraded or damaged Gun and Cable Maintenance See appropriate Operator s Manual Procedure for Removing Feedplate from Wire Feeder 1 Loosen the clamping collar screw using a 3 16 Allen wrench The clamping collar screw is accessed from the bottom of the feedplate It is the screw which is perpendicular to the feeding direction 9 Loosen the retaining screw which is also accessed from bottom of feeder using a 3 16 Allen wrench Continue to loosen the screw until the feedplate can be easily pulled off of the wire feeder POWER FEED 10M DUAL WIRE FEEDER LINCOLN E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE AA 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
117. xtend their length All system equipment must be connected to a con trol cable NOTE The maximum cable length between Power Source and Wire Feeder is 100 30 5m INSTALLATION Typical Bench Feeder Connection Control cable is connected from the Power Wave 455 output receptacle to the input receptacle on the back of the Wire Drive CONTROL CABLE SPECIFICATIONS It is recommended that only genuine Lincoln control cables be used at all times Lincoln cables are specifi cally designed for the communication and power needs of the Power Wave 455 Power Feed system The use of non standard cables especially in lengths greater than 25 feet 7 6m can lead to communication problems system shutdowns poor motor accelera tion poor arc starting and low wire driving force wire feeding problems Lincoln control cables are copper 5 conductor cable in a SO type rubber jacket There is one 20 gauge twist ed pair for network communications This pair has an impedance of approximately 120 ohms and a propa gation delay per foot of less than 2 1 nanoseconds There are two 12 gauge conductors that are used to supply the 40 VDC to the network The fifth wire is 18 gauge and is used as an electrode sense lead AVAILABLE CABLE ASSEMBLIES K1543 Control cable only Available in lengths of 8 2 4m 16 4 9m 25 7 6m 50 15 2m and 100 30 5m POWER FEED 10M DUAL WIRE FEEDER LINCOLN A 3 OUTPUT CABLES CONNECTIONS
118. ze exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source 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 high 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 e AC Welder with Reduced

Lincoln Electric IM916 User's Manual

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