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IM584-D
PowerFeed10 WireDrive & ControlBox
August, 2007
Boom Mount or Bench Model
For use with: Power Feed 10 Control Box - Boom Mount Code 10436, 10615
Power Feed 10 Wire Drive - Boom Mount Code 10437,10616, 10782
Power Feed 10 Boom Package Code 10435, 10612 (Generic), 10493, 10613 (12’ Zipline), 10494, 10614 (16’ Zipline),
10779 (Generic), 10767, 10780 (12’ Zipline), 10768, 10781 (16’ Zipline)
Power Feed 10 Bench Model Code 10438, 10617, 10760,10783
Safety Depends on You
Lincoln arc weldi
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i i SAFETY WARNING 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 YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a.Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mate
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque dʼincendie dû aux étincelles
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• 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 Linco
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vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ...............................................................................................................A-2 Mounting the Wire Drive Unit .................................................
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vii TABLE OF CONTENTS Page Troubleshooting ..............................................................................................Section E Safety Precautions ...............................................................................................................E-1 Troubleshooting Guide .........................................................................................................E-2 Procedure for Replacing PC Boards ......................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – Power Feed 10 Wire Drive & Control Box WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO Wire Size Wire Size Low Speed Solid Cored High Speed Solid Cored K1540-1 Power Feed 10 50-800 IPM .025 - 3/32 in. .035 - .125 in 75 - 1200 IPM .025 - 1/16 in. .035 - 5/64 in. K1540-2 Wire Drive (1.27-20.3 m/m) (0.6 - 2.4 mm) (0.9 - 3.2 mm) (2.03 - 30.5 m/m) (0.6 - 1.6 mm) (0.9 - 2.0 mm) K1538-1, Power Feed 10 50-800
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A-2 A-2 INSTALLATION ELECTRODE ROUTING SAFETY PRECAUTIONS ELECTRIC SHOCK can The electrode supply may be either from reels, Readi- Reels, spools, or bulk packaged drums or reels. kill. Observe the following precautions: • Only qualified personnel should per- form this installation. a) The electrode must be routed to the wire drive unit so that the bends in the wire are at a mini- • Turn off the input power to the power source at the mum, and also that the force required to pull the disconn
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A-3 A-3 INSTALLATION 5. Remove plug button taped to inside of Control Box installed in the Control Box. An Input/Output and insert it into hole on front panel of the Wire Receptacle Kit, K1548-1, is available for this purpose. Drive. Instructions for installing the receptacles in a Control Box are included with the kit. MOUNTING THE CONTROL BOX (BOOM Alternately, a bench feeder can be converted to a OR SEPARATED BENCH MODELS) non-typical boom system by installing an output receptacle in a W
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A-4 A-4 INSTALLATION Typical Bench Feeder Connection: AVAILABLE CABLE ASSEMBLIES Control cable is connected from the Power Wave 455 K1543 Control cable only. Available in lengths of output receptacle to the input receptacle on the back 8'(2.4m), 16'(4.9m), 25'(7.6m), 50'(15.2m) and of the Wire Drive. 100'(30.5m). K1544 Control cable and a 3/0 (85 mm2 ) electrode Typical Boom Feeder Connection: cable with stud terminal. It is rated at 600 amps, 60% duty cycle and is available in One control c
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A-5 A-5 INSTALLATION Connect the one end of the electrode cable, to the power source output terminal of the desired polarity. WIRE DRIVE GEAR RATIO (HIGH Connect the other end of the electrode cable to the OR LOW SPEED) connection bar at the front of the wire drive feed plate using the provided bolt and lockwasher. The elec- The speed range capability and drive torque of the trode cable lug must be against the feed plate. Be Power Feed 10 wire drive can be easily and quickly sure the cable
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A-6 A-6 INSTALLATION RATIO CHANGE PROCEDURE: head (2 screws). 1) Pull open the Pressure Door. b) Locate the 8-position DIP switch near the top edge of the PC board, centered left to right. 2) Remove the Phillips head screw retaining the pin- The setting will be made on the right most ion gear to be changed and remove the gear. If switch, S8. the gear is not easily accessible or difficult to remove, remove the feed plate from the gearbox. c) Using a pencil or other small object, slide the
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A-7 A-7 INSTALLATION ON S1 DIP SWITCH SETUP 1 2 3 456 7 8 SETTING DIP SWITCHES IN THE ON S2 CONTROL BOX 1 2 3 456 7 8 There are two DIP switch banks on the mother board of the Control Box. They are labeled S1 and S2 and FIGURE A.3 are located and oriented as shown in Figure A.3. S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only) Switch Off On 1 Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting) 2 Network Group ID, LSB (
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A-8 A-8 INSTALLATION S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up) Switch Off On 1 Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting) 2 Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting) 3 Spare 4 Spare 5 Spare 6 Must be off for normal operation Adjust lower limits 7 Must be off for normal operation Adjust upper limits 8 Must be on for European units only S1 DIP Switch Bank on
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A-9 A-9 INSTALLATION S1 DIP Switch Bank on Control Box Motherboard (For software version S24456) Switch Off On 1 Standard speed gearbox limits adjustable High speed gearbox limits adjustable 2 WFS Display = inches/minute WFS Display = meters/minute 3 Left Display is always preset WFS Left Display is preset WFS when weld current is not flowing Left Display is actual weld current when weld current is flowing CC modes override this switch regardless of position. Left Display is always preset wel
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A-10 A-10 INSTALLATION Setting Wire Drive Acceleration Rate Using (All software versions) DIP Switch S1 on the Control Box Motherboard DIP SWITCH 6 DIP SWITCH 7 DIP SWITCH 8 Acceleration 1 (slow) Off Off On Acceleration 2 Off On Off Acceleration 3 Off On On Acceleration 4 On Off Off Acceleration 5 (fast ) (factory setting) Off Off Off SETTING DIP SWITCHES IN THE WIRE ON 1 2 3 456 7 8 DRIVE There is one DIP switch bank on the control board of the wire drive. Itʼs labeled S1 and is located and
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A-11 A-11 INSTALLATION shaft. (Do Not exceed maximum wire size rating of WIRE FEED DRIVE ROLL KITS the wire drive). NOTE: The maximum rated solid and cored wire 7) Install Outer Wire Guide by sliding over locating sizes and selected drive ratios are shown on pins and tightening in place. the SPECIFICATIONS in the front of this sec- tion. 8) Engage upper drive rolls if they are in the “open” position and close Pressure Door. The electrode sizes that can be fed with each roll and TO SET DRIV
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A-12 A-12 INSTALLATION Magnum 200 / 300 / 400 Guns GENERAL GUN CONNECTION GUIDELINES The easiest and least expensive way to use Magnum 200/300/400 guns with the Power Feed 10 wire feeder GUN CONNECTIONS - GENERAL is to order them with the K466-10 connector kit, or to buy a completely assembled Magnum gun having the K466-10 connector (such as the K497-21 dedicated 4-roll feed plates are equipped with a brass connector Magnum 400). bar at the gun-end of the feed plate to allow a bolted brass-to
