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POWER FEED 15M
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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 opera-
tion 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 careful.
• 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
For use with machines having Code Number : 10940
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
R
NRTL/C
Copyright © 2005 Lincoln Global Inc.
IM761
September, 2005
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Related Manuals for Lincoln Electric POWER FEED 15M IM761
Summary of Contents for Lincoln Electric POWER FEED 15M IM761
- Page 1 September, 2005 For use with machines having Code Number : 10940 This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You...
- Page 2 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.
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Page 3: Electric Shock Can Kill
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”... - Page 4 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.
- Page 5 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...
- Page 6 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.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Installation........................Section A Technical Specifications .......................A-1 Safety Precautions .......................A-2 Location ..........................A-2 High Frequency Protection ....................A-2 Digital Welding System Components ...................A-2 Control Cable Connection ....................A-3 Weld Cable Size and Table ....................A-3 Coaxial Weld Cable ......................A-4 Electrode Polarity .........................A-4 Shielding Gas Connection ....................A-4 Changing The Drive Motor Gears ..................A-5 Wire Drive Configuration ......................A-6... -
Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS – POWER FEED 15M K2196-1 INPUT VOLTAGE and CURRENT MODEL DUTY CYCLE INPUT VOLTAGE ± 10% INPUT AMPERES 35% rating K2196-1 60% rating 40 VDC Domestic 100% rating ELECTRODE DIAMETERS and SPEED RANGE PROCESS ELECTRODE DIAMETER RANGE OUTPUT RANGE (AMPERES) WIRE FEED SPEED RANGE .023 - .052"... -
Page 9: Safety Precautions
INSTALLATION SAFETY PRECAUTIONS HIGH FREQUENCY PROTECTION CAUTION WARNING Locate the Power Feed 15M away from radio con- ELECTRIC SHOCK CAN KILL. trolled machinery. The normal operation of the • ONLY QUALIFIED PERSONNEL Power Feed 15M may adversely affect the operation SHOULD PERFORM THIS... -
Page 10: Control Cable Connection
INSTALLATION WELD CABLE SIZE CONTROL CABLE CONNECTION: Digital Control Cable: Figure A.3 Table A.1 located below are copper cable sizes rec- ommended for different currents and duty cycles. Power Source W ire Feeder Lengths stipulated are the distance from the welder to work and back to the welder again. -
Page 11: Coaxial Weld Cable
INSTALLATION SHIELDING GAS CONNECTION COAXIAL WELD CABLE WARNING Coaxial welding cables are specially designed welding cables for pulse welding or STT welding. Coaxial weld CYLINDER may explode if cables feature low inductance, allowing fast changes in the damaged. weld current. Regular cables have a higher inductance which may distort the pulse or STT waveshape. -
Page 12: Changing The Drive Motor Gears
INSTALLATION CHANGING THE DRIVE MOTOR GEAR RATIO 11. Use a 5/16" nut driver to remove the four screws and washers holding the insulated panel to the sheet metal bracket. WARNING • Turn off input power at the weld- 12. Lift the wire drive assembly partially out of the wire feeder. -
Page 13: Wire Drive Configuration
INSTALLATION WIRE DRIVE CONFIGURATION 10. Tighten the socket head cap screw. (See Figure A-6) 11. Insert the welding gun into the gun bushing and Changing the Gun Receiver Bushing tighten the thumb screw. WARNING PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES ELECTRIC SHOCK can kill. -
Page 14: Remote Sense Lead Specification
INSTALLATION REMOTE SENSE LEAD SPECIFICATIONS Welding with Multiple Arcs: ( See Figure A.7) Special care must be taken when more than one arc is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture. -
Page 15: Operation
OPERATION SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. INPUT POWER WARNING • ELECTRIC SHOCK CAN KILL. Unless using COLD FEED fea- ture, when feeding with gun trig- ger, the electrode and drive mechanism are always electri- cally energized and could... -
Page 16: Definition Of Welding Terms
OPERATION DEFINITION OF WELDING TERMS GMAW-STT • Gas Metal Arc welding-(Surface Tension Transfer) NON-SYNERGIC WELDING MODES SMAW • A Non-synergic welding mode requires all welding • Shielded Metal Arc welding process variables to be set by the operator. FCAW SYNERGIC WELDING MODES •... -
Page 17: General Description
OPERATION GENERAL DESCRIPTION RECOMMENDED PROCESSES The Power Feed 15M is best suited for alloy elec- The Power Feed 15M is a portable wire feeder for trodes, out-of-position work, root welding and general customers seeking high end arc performance all fabrication. packed in a rugged stainless steel case. -
Page 18: Making A Weld With Waveform Technology Power Sources
The user adjusts WFS according to factors responsibility of the builder/user. Many variables such as weld size, penetration requirements, heat beyond the control of The Lincoln Electric Company input, etc. The power source then uses the WFS set- affect the results obtained in applying these pro- ting to adjust its output characteristics (output voltage, grams. -
Page 19: Constant Voltage (Cv) Welding
OPERATION PULSE WELDING CONSTANT VOLTAGE (CV) WELDING (See figure B..2) (See figure B.1) Pulse welding procedures are set by controlling an over- • Synergic CV: all "arc length" variable. When pulse welding, the arc Synergic welding allows for easy procedure setting. voltage is highly dependent upon the waveform. -
Page 20: Stt Synergic Welding
OPERATION STT SYNERGIC WELDING The Figures B.3 and B.3a is the waveshape of current for the process. They are not drawn to scale, and are intended only for the purpose of showing how the vari- ables effect the waveform. FIGURE B.3 Trim 1.50 Trim 1.50 Current... -
Page 21: Case Front Controls
OPERATION CASE FRONT CONTROLS The voltage display shows the actual average arc volt- (See Figure B.3b) age during the welding. 1. WIRE FEED SPEED/AMMETER DISPLAY-This After welding, the meter holds the actual average arc meter displays either the wire feed speed or current voltage for 5 seconds. - Page 22 OPERATION Synergic CV Voltage Display MSP-3 Multi-Process Panel Synergic CV programs feature an ideal voltage best The center portion of the Power Feed-15M front case suited for most procedures. Use this voltage as a enables selection of weld modes and fine tuning of starting point for the weld procedure and adjust if weld parameters within each weld mode.
- Page 23 OPERATION OSTFLOW Arc Control The Postflow setting adjusts the amount of time the Arc Control is a generic control that allows fine tuning shielding gas flows after the trigger is released and the waveform. The function of Arc Control depends welding current is turned off.
- Page 24 B-10 B-10 OPERATION Crater Spot The Crater function sets an endpoint WFS and The Spot function is useful when making many short, Voltage to achieve over a specified time period. At repetitive welds. When the Spot function is active, the the end of the weld when the trigger is released, the power source will weld for a set time after the trigger crater time begins and the WFS and Voltage values...
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Page 25: Extended Features Menu
B-11 B-11 OPERATION EXTENDED FEATURES MENU The stall factor controls the torque of the wire drive inside the Power Feed 15M when using a push-pull The Extended Features Menu gives access to the set- gun. The Power Feed 15M is factory set to generate up configuration. -
Page 26: Internal Controls
B-12 B-12 OPERATION • When inching with the gun trigger, electrode INTERNAL CONTROLS (Figure B.5) and drive mechanism are "hot" to work and ground and could remain energized several sec- COLD FEED/GAS PURGE SWITCH onds after the gun trigger is released. •... -
Page 27: Flow Meter
B-13 B-13 OPERATION FLOW METER The flowmeter shows the flow rate of shielding gas and has a valve to adjust the flow. The flow meter is calibrated for CO , Ar, and CO /Ar blends. The middle of the ball indicates the flow rate of shielding gas. Adjust the flow rate by turning the valve at the bottom of the meter. - Page 28 B-14 B-14 OPERATION 2 STEP - 4 STEP - TRIGGER OPERATION EXAMPLE 1 - 2 STEP TRIGGER: Simple operation The simplest trigger operation occurs with a 2 Step trigger and the Start, Crater and Burnback functions The 2 Step - 4 Step switch changes the -STEP all set to OFF.
- Page 29 B-15 B-15 OPERATION UPSLOPE: EXAMPLE 2 - 2 STEP TRIGGER: Improved Arc Start Once the wire touches the work and an arc is estab- and Arc End. Tailoring the arc start and arc end is a lished, both the machine output and the wire feed common method for reducing spatter and improving speed ramp to the weld settings throughout the start weld quality.
- Page 30 B-16 B-16 OPERATION EXAMPLE 3 - 2 STEP TRIGGER: Customize Arc WELD: Start, Crater and Arc End. Sometimes it is advanta- After upslope, the power source output and the wire geous to set specific arc start, crater and arc ending feed speed continue at the weld settings.
- Page 31 B-17 B-17 OPERATION EXAMPLE 4 – 4 STEP TRIGGER: Trigger Interlock The 4 step trigger can be configured as a trigger inter- lock. Trigger interlock adds to the welder’s comfort when making long welds by allowing the trigger to be released after an initial trigger pull.
- Page 32 B-18 B-18 OPERATION UPSLOPE: EXAMPLE 5 - 4 STEP TRIGGER: Manual control of During upslope, the power source output and the wire Start and Crater times with Burnback ON. The 4 step feed speed ramp to the weld settings throughout the trigger sequence gives the most flexibility when the start time.
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Page 33: Accessories
ACCESSORIES FACTORY INSTALLED EQUIPMENT • K1500-2 Gun Receiver Bushing. DRIVE ROLL KITS USED • Drive Roll Kits (Includes drive rolls and inner wire guide necessary to feed the identified wire size and type). KP KIT WIRE TYPE ELECTRODE SIZE KP1696-030S Steel Wires: .023-.030 (0.6-0.8mm) KP1696-035S... -
Page 34: Maintenance
MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. • Turn the input power to the welding power source off at the fuse box before working in the terminal strip. -
Page 35: 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. - Page 36 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION Linc-Net System Error Codes Fault Code Description Possible Adjustments 1. The wire feeder has not received 1. Verify the power source is operat- Err 006 ing properly (Status light steady a recognition command from the...
- Page 37 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION ArcLink System Error Codes Description Possible Adjustments Fault Code 1. Verify the power source reconnect Err 43 Capacitors are out of balance panel wiring matches the input power.
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Page 38: Parts
4. The electrode is rusty or dirty. 4. Use only clean electrode. Use quality electrode, like L-50 or L-56 from Lincoln Electric. 5. The contact tip is partially melted 5. Replace the contact tip. or has spatter. - Page 39 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION Output Problems Variable or "hunting" arc. 1. Wrong size, worn and/or melted 1. Replace the contact tip. contact tip. 2. Worn work cable or poor work 2.
- Page 40 DIAGRAMS FLEX POWER FEED 15M...
- Page 41 DIMENSION PRINT POWER FEED 15M...
- Page 42 NOTES POWER FEED 15M...
- Page 43 NOTES POWER FEED 15M...
- Page 44 NOTES POWER FEED 15M...
- Page 45 NOTES POWER FEED 15M...
- Page 46 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
- Page 47 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
- Page 48 • 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...