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IM916
July, 2010
Power Feed™ 10M Dual Wire Feeder
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
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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 mat
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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! 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 Electrode Routing.............................................................
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vii vii TAbLE OF CONTENTS Maintenance ....................................................................................................Section D Safety Precautions ...............................................................................................................D-1 Routine Maintenance ...........................................................................................................D-1 Avoiding Wire Feeding Problems.........................................................
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A-1 A-1 INSTALLATION 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) CONTROL bOx, WIRE DRIVE AND COMPLETE UNITS SPEC.#
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A-2 A-2 INSTALLATION Typical bench Feeder Connection: SAFETY PRECAUTION Control cable is connected from the Power Wave® ELECTRIC SHOCK can 455 output receptacle to the input receptacle on the kill. back of the Wire Drive. • Only qualified personnel should per- form this installation. CONTROL CAbLE SPECIFICATIONS • Turn off the input power to the power source at the It is recommended that only genuine Lincoln control disconnect switch or fuse box before working on this equipment. Turn off th
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A-3 A-3 INSTALLATION For additional Safety information regarding the elec- OUTPUT CAbLES, CONNECTIONS trode and work cable set-up, See the standard "SAFE- AND LIMITATIONS TY INFORMATION" located in the front of the Connect a work lead of sufficient size and length (Per Instruction Manuals. 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 eq
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A-4 A-4 INSTALLATION The Power Feed™ 10M Dual Wire Feeder is factory VOLTAGE SENSING set for Electrode Positive welding. The best arc performance occurs when the Power Waves® have accurate data about the arc conditions. Most welding procedures use Electrode Positive weld- Depending upon the process, inductance within the ing. Some Innershield procedures may use Electrode electrode and work lead cables can influence the volt- Negative welding. For most applications, the Power age apparent at
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A-5 A-5 INSTALLATION Work Voltage Sensing WIRE DRIVE GEAR RATIO (HIGH The standard Power Wave® 455’s default to the work OR LOW SPEED) stud (work sense lead disabled) For processes requiring work voltage sensing, con- The speed range capability and drive torque of the nect the (21) work voltage sense lead (K940) from the Power Feed™ wire drives can be easily and quickly Power Wave® work sense lead receptacle to the work changed by changing the external drive gear. The piece. Attach the sense
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A-6 A-6 INSTALLATION 5. Remove the small gear from the output shaft. CHANGING THE WIRE DRIVE GEAR RATIO Lightly cover the output shaft with engine oil or equivalent. Install gear onto output shaft and Changing the ratio requires a gear and a dip switch secure with flat washer, lock washer, and Phillips setting change. The Power Feed™ Wire Feeders are head screw which were previously removed. shipped with both high speed and a low speed gears. As shipped from the factory, the low speed (hig
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A-7 A-7 INSTALLATION • Insert inner Wire Guide, groove side out, over the WIRE FEED DRIVE ROLL KITS two locating pins in the feedplate. NOTE: The maximum rated solid and cored wire sizes • Install each drive roll by pushing over shaft until it and selected drive ratios are shown on the butts up against locating shoulder on the drive roll SPECIFICATIONS in the front of this section. shaft. (Do Not exceed maximum wire size rating of the wire drive). The electrode sizes that can be fed with e
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A-8 A-8 INSTALLATION Magnum 550 Guns 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- The easiest and least expensive way to use the ate holes in connector. Tighten gun by turning Magnum 550 guns with Power Feed™ 10 Dual wire large nut on gun clockwise. feeders is to order the gun with the K613-7 connector kit, and install a K1500-3 gun connection kit to the c. For GMA Gun Cables with separate gas fit
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A-9 A-9 INSTALLATION Flow Sensor Kit installation is as follows: WIRE SPINDLE PLACEMENT 1. Remove rear access door of the wire feeder case. The reel stand provides two mounting locations for the 2. Locate the shutdown circuit leads inside feeder 2 inch diameter wire reel spindle to accommodate var- case cavity (refer to table A.4). ious reel sizes. Each mounting location consists of a Note: The leads will be connected together with tube in the center of the reel stand, and locating slots insu
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A-10 A-10 INSTALLATION Shown with ExAMPLES OF CONNECTING AN • K2230-2 Power Feed™ 10M Single Wire Feeder ARCLINK POWER WAVE SYSTEM • K1780-2 PF™-10/R • K2203-1 Power Wave® 455M/STT ArcLink Power Wave® products may be configured in • K2205-1 Wire Drive Module many different ways. The flexible system allows multi- ple wire feeders to be connected to the same power Hard Automation System source. The diagrams represent some of the common methods for connecting ArcLink Products. Important: Bench
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b-1 b-1 OPERATION SAFETY PRECAUTIONS COMMON WELDING AbbREVIATIONS Read entire Operation section before operating the Power Feed™ 10M Dual WFS Wire Feeder. • Wire Feed Speed WARNING CC • Constant Current ELECTRIC SHOCK can kill. • Do not touch electrically live CV parts or electrode with skin or • Constant Voltage wet clothing. Insulate yourself from work and ground. GMAW (MIG) • Always wear dry insulating • Gas Metal Arc welding gloves. GMAW-P (MIG) FUMES AND GASES can be • Gas Metal Arc welding
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b-2 b-2 OPERATION DUAL HEAD UNIT PRODUCT DESCRIPTION The Power Feed™ 10M Dual Wire Feeder unit con- Two Control PC boards: one board supports user sists of a user interface and two wire drives. This unit interface and wire drive functions and second board will be available as a bench model or a boom model. supports second wire drive functions. The Power Feed™ 10M Dual Wire Feeder is a high RECOMMENDED PROCESSES AND performance, digitally controlled, modular wire feeder. EQUIPMENT Properly equip
