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IM689-A
Power Feed 10 Robotic
May, 2007
K1780- 1
For use with machines having code numbers: 10729,10801
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 b
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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 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 ho
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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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 T Th ha an nk k Y Yo ou u ••• 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, purchas
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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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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – Power Feed 10 Robotic-K1780-1 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 K1780-1 Power Feed 10 50-800 IPM .025 - 3/32 in. .035 - .120 in 75 - 1200 IPM .025 - 1/16 in. .035 - 5/64 in. (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 CONTROL BOX, WIRE DRIVE AND COMPLETE UNITS SPEC.# TYPE INPUT POWER
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS ELECTRODE ROUTING WARNING The electrode supply may be either from reels, Readi- Reels, spools, or bulk packaged drums or reels. Observe the following precautions: ELECTRIC SHOCK can kill. • Do not bend the conduit more than 45°, and to use the minimum amount of conduit necessary for the • Only qualified personnel should perform this installation. wire reel to connect to the wire feeder. • The electrode is "hot" while welding and must be • Turn off t
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A-3 A-3 INSTALLATION SHIELDING GAS CONNECTION When using an inverter type power source, Use the largest welding (electrode and work) cables that are practical. At least 2/0 copper wire - even if the aver- WARNING age output current would not normally require it. When pulsing, the pulse current can reach very high CYLINDER may explode if damaged. levels. Voltage drops can become excessive, leading • Keep cylinder upright and chained to poor welding characteristics, if undersized welding to su
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A-4 A-4 INSTALLATION WIRE DRIVE GEAR RATIO (HIGH OR LOW CONTROL CABLE SPECIFICATIONS SPEED) It is recommended that genuine Lincoln control cables The speed range capability and drive torque of the be used at all times. Lincoln cables are specifically Power Feed wire drives can be easily and quickly designed for the communication and power needs of changed by changing the external drive gear. The the Power Wave / Power Feed system. The use of Power Feed Wire Feeders are shipped with both high
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A-5 A-5 INSTALLATION CHANGING THE WIRE DRIVE RATIO 5. Remove the small gear from the output shaft. Lightly cover the output shaft with engine oil or equivalent. Install gear onto output shaft and secure WARNING with flat washer, lock washer, and Phillips head screw which were previously removed. ELECTRIC SHOCK can kill. 6. Tighten the screw on lower right face of feed plate. • Turn off power to the power source at the disconnect switch. 7. Re-attach feed plate to wire feeder if removed in St
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A-6 A-6 INSTALLATION 6. Install each drive roll by pushing over shaft until it WIRE FEED DRIVE ROLL KITS butts up against locating shoulder on the drive roll shaft. (Do Not exceed maximum wire size rating of NOTE: The maximum rated solid and cored wire the wire drive). sizes and selected drive ratios are shown on the SPECIFICATIONS in the front of this sec- 7. Install Outer Wire Guide by sliding over locating tion. pins and tightening in place. The electrode sizes that can be fed with each
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A-7 A-7 INSTALLATION GUN RECEIVER BUSHINGS AND CONDUIT ADAPTERS ADAPTERS The K1546-1 and K1546-2 Adapter for use with Lincoln Magnum conduit (K515 or 565) and E-Beam The Power Feed wire feeders are equipped with facto- conduit. The K1546-1 is to be used for wire sizes ry installed K1500-2 gun connection kits. These kits (.023 - 1/16), K1546-2 is to be used for wire sizes are for guns having a Tweco #2-#4 type connector. The Power Feed 10/R has been designed to make (1/16 - .120) connecting a
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A-8 A-8 INSTALLATION Feeding Electrode and Brake Adjustment 3. If the only result is drive roll slippage, disengage the gun, pull the gun cable forward about 6" (150 mm). 1. Turn the Reel or spool until the free end of the elec- There should be a slight waviness in the exposed trode is accessible. If using a drum or large reel, wire. If there is no waviness, the pressure is too supply the electrode to the PF-10/R with an elec- low. Increase the pressure setting 3 turns, recon- trode conduit.
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B-1 B-1 OPERATION SAFETY INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section of operat- The Power Feed 10 Robotic is a high performance, ing instructions before operating the machine. digitally controlled, modular wire feeder. Properly equipped, it can support the GMAW, GMAW-P and WARNING FCAW processes. The Power Feed wire feeders are designed to be a part of a modular, multi-process ELECTRIC SHOCK can kill. welding system. The Power Feed 10 Robotic is a 4 • Unless using co
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C-1 C-1 ACCESSORIES PLATFORM COMMONALITIES OPTIONAL EQUIPMENT • Power Feed 10 series Feedhead. • CGA gas connections. • KP1505 Drive Roll and Wire Guide Kits • Quick connect water connections. • KP1507 Drive Roll and Wire Guide Kits • Works with all PowerWave ArcLink systems. “It is not compatible with the PowerWave 350, 450 or 500 The KP1507 series of drive roll kits contain a number or Linc-net PowerWave 455ʼs” of components, in addition to the drive rolls, to opti- mize the wire feeder for al
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D-1 D-1 MAINTENANCE AVOIDING WIRE FEEDING PROBLEMS SAFETY PRECAUTIONS Wire feeding problems can be avoided by observing the following gun handling and feeder set up proce- dures: WARNING a) Do not bend the conduit more than 45°. ELECTRIC SHOCK can kill. • Do not touch electrically live parts such b) Keep the minimum amount of conduit necessary as output terminals or internal wiring. for the wire reel to connect to the wire feeder. • When inching with gun trigger, electrode and drive mechanism
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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 RECOMMENDED POSSIBLE CAUSE (SYMPTOMS) COURSE OF ACTION Rough wire feeding or wire not 1. Gun cable kinked and / or twist- feeding but drive rolls are turning. ed. 2. Wire jammed in gun and cable. Check for mechanical restric- tions in feeding path. 3. Check for current position of drive rolls relative to split wire guide groove. 4. Drive rolls may not be seated properly. 5. Gun cable dirty, clean
