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IM850-A
April, 2005
POWER FEED 10S
For use with machines having Code Numbers: 11063, 11064, 11127
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be care
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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 ELECTRIC SHOCK can ARC RAYS can burn. 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 SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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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 l’on 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 d’incendie 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! 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
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vi vi TABLE OF CONTENTS Page Product Description.........................................................................................................................1 Recommended Processes ..............................................................................................................1 Process Limitations .........................................................................................................................1 Equipment Limitations...............................
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1 1 PRODUCT DESCRIPTION PRODUCT SUMMARY The Power Feed 10S series of Automatic Wire Drives are designed for hard automation, submerged arc welding. The heavy-duty gearbox and feed plate have many years of proven reliability while a new perma- nent magnet motor has been added. The Power Feed 10S wire drives consist of a high torque motor and gearbox assembly with a heavy-duty feed plate housing knurled drive rolls for positive, accurate wire feeding of heavy welding wire. The Power Feed 10S has
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2 2 GENERAL INFORMATION DESIGN FEATURES � Closed-loop speed control. � Knurled drive rolls. � Heavy cast aluminum gearbox housing and feed plate assembly. � Wire straightener. � 32Vdc permanent magnet, high torque motor. � Conversion kit included to change speed range. � Voltage sense leads included for precision welding performance. LOCATION OF COMPONENTS WIRE DRIVE AND COMPONENTS CENTERLINE OF MOUNTING BRACKET TOP VIEW ISOVIEW (REF. ONLY) MOTOR AND LEAD CENTERLINE OF WIRE CONNECTIONS SIDE V
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3 3 SPECIFICATIONS TECHNICAL SPECIFICATIONS - POWER FEED 10S Spec. Type 142:1 Speed Ratio 95:1 Speed Ratio 57:1 Speed Ratio Wire Size Wire Size Wire Size Speed Solid Cored Speed Solid Cored Speed Solid Cored K2312-1 Power Feed 10-200 7/32 5/32 10-300 1/8 5/32 10-450 1/16 3/32 10S Wire Feeders - Input Voltage and Current Voltage Input Amperes 32V DC 7 Amps (max.) PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT K231
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A-1 A-1 INSTALLATION SAFETY PRECAUTIONS Read this entire installation section before you start installation. WARNING ELECTRIC SHOCK can kill. � Only qualified personnel should per- form this installation. � Turn the input power OFF at the dis- connect switch or fuse box before working on this equipment. Turn off the input power to any other equip- ment connected to the welding sys- tem at the disconnect switch or fuse box before working on the equip- ment. � Do not touch electrically hot part
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A-2 A-2 INSTALLATION POWER WAVE AC/DC 1000AMP SUBARC MOUNTING DIMENSIONS SYSTEM CONNECTIONS The PF-10S can be mounted by using the four 3/8-16 (See Figure A.1) tapped holes or the two 0.562 through holes. See mounting hole locations (Figure A.2). 1- Work cable connection 3- 14 pin wire feeder control cable 4- 5 pin Arclink control cable to user interface 7- Electrode cable connection FIGURE A.1 POWER WAVE AC/DC 1000 K2344-1 POWER FEED10SFC ARC 1 CONTROL BOX CONTROL K2362-1 1 3 5 2 4 6 8
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R O T A T E R A-3 A-3 INSTALLATION 5. Carefully disconnect the Motor leads from the har- CHANGING WIRE DRIVE CONFIGURATION ness by pulling the quick-connect terminals apart. The POWER FEED-10S Wire Drives can be reconfig- ured to fit in any hard automation application. 6. Reverse the motor leads and reconnect the quick- connect terminals (see Wiring Diagram). The POWER FEED-10S Wire Drives can be reconfig- ured in such a way that the wire feed direction is 7. Carefully replace the wire harnes
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A-4 A-4 INSTALLATION ELECTRODE AND WORK REMOTE SENSE LEAD SPECIFICATIONS CONNECTIONS The Power Feed 10S has sense lead connections at Due to the Power Wave AC/DC”s ability to produce the Connection Box mounted to the motor. These either a DC positive, DC negative or AC output the elec- sense leads are critical to the accuracy of the Power trode and work connections do not need to be reversed Wave welding process. Ring terminals are provided at for the different polarities. Additionally no DIP
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A-5 A-5 INSTALLATION WELDING WITH MULTIPLE ARCS If the voltage sensing is enabled but the sense leads are missing, improperly connected, or if the electrode polarity switch is improperly configured Special care must be taken when more than one arc extremely high welding outputs may occur. is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each In extremely sensitive applications requiring voltage power source requires a work lead from the wor
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A-6 A-6 INSTALLATION GEAR RATIO CONVERSION KITS (SEE INSTRUCTIONS INCLUDED WITH CON- VERSION KIT) 1. Remove the 2 hex head screws and the 2 slot head screws holding the Motor to the Wire Drive Gearbox assembly. 2. Remove existing Adapter Plate and Motor Assembly. 3. Take the two long screws removed in step 1 and screw one into each of the tapped holes located on the face of fiber input helical gear. Insert the screws through the full thickness of the gear, and using a screwdriver wedged between
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C-1 C-1 ACCESSORIES K2311-1 MOTOR CONVERSION KIT (FOR 142:1 NA STYLE WIRE DRIVES)--This conver- tion kit converts old NA style wire drives. 1. Remove the 2 hex head screws and the 2 slot head screws holding the Motor to the Wire Drive Gearbox assembly. 2. Remove existing Adapter Plate and Motor Assembly. 3. The Conversion Kit Motor is shipped configured for a 142:1 gear ratio. The existing gearbox must be con- figured for a 142:1 gear ratio for the Conversion Kit to assemble correctly. If bot
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D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS SENSE LEAD FUSE There should never be any current flowing through the sense leads! There is a fuse located in the sense WARNING lead circuit that is mounted in the wire drive Connection Box which protects the sense lead circuit ELECTRIC SHOCK can kill. from weld current due to incorrect configuration. If this fuse ever opens, check the sense lead configuration to • Only Qualified personnel should ensure proper connections. The fuse must be perform this m
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E-1 E-1 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. _______________________________________________________________
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E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS Drive rolls turn, but wire will not 1. Wire jammed or kinked on route feed or wire feeding is rough or through wire drive. Remove wire uneven. from wire drive, then feed in new wire. Note any obstruction. 2. Incorrect drives rolls and/or guide tubes, or incorrect pres- sure setting. Ensure drive rolls and/or g
