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Lincoln Electric ACTIV8 Operator's Manual

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Operator's Manual
ACTIV8
Register your machine:
www.lincolnelectric.com/registration
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10085-A
| Issue Date May-16
© Lincoln Global, Inc. All Rights Reserved.
™
For use with machines having Code Numbers:
11770, 12198

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Summary of Contents for Lincoln Electric ACTIV8

  • Page 1 Operator’s Manual ACTIV8 ™ For use with machines having Code Numbers: 11770, 12198 Register your machine: www.lincolnelectric.com/registration Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10085-A | Issue Date May-16...

  • Page 2: Safety Precautions

    THANK YOU FOR SELECTING A QUALITY PRODUCT BY KeeP your head out oF the Fumes. LINCOLN ELECTRIC. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety...

  • Page 3: California Proposition 65 Warnings

    American Welding Society, P.O. Box 351040, Miami, Florida 33135 or ELECTRIC AND CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAGNETIC FIELDS MAY booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS BE SURE THAT ALL INSTALLATION, OPERATION, 2.a.

  • Page 4: Electric Shock Can Kill

    S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the the gas and pressure used.
  • Page 6 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding shielding the supply cable of permanently installed welding Equipment. It is for use with other Lincoln Electric equipment. It is equipment, in metallic conduit or equivalent. Shielding should be designed for industrial and professional use.

  • Page 7: Table Of Contents

    Procedure to Install Drive Rolls and Wire Guides ..............A-4 Pressure Arm Adjustment ....................A-5 Loading Spools of Wire ......................A-5 Gun Connection ........................A-6 Power Source to ACTIV8™ Cable Connection Diagrams ........A-7 thru A-9 Procedure to Install Conduit Bushing for the Wire Feeder Unit..........A-10 ________________________________________________________________________________ Operation.........................Section B Safety Precautions .......................B-1...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – ACTIV8™ (K2999-1) INPUT VOLTAGE 15-110 V DC (4 Input Amperes) RATED CURRENT 330 Amps 60% Duty Cycle ELECTRODE DIAMETERS and SPEED RANGE Electrode Size Speed Range Electrode 0.023 - 0.052" Solid Steel (0.6 - 1.3 mm) 50 - 800 ipm 0.035 - 5/64"...

  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS The ACTIV8 is rated IP23 and is suitable for outdoor use in the upright position. WARNING The handle of the ACTIV8™ is intended for moving the wire feeder about the work place only. ELECTRIC SHOCK CAN KILL.

  • Page 10: Trigger Connector

    There is one circular connector for the gun trigger on adapter between regulator and cylinder valve. If the front of the ACTIV8™ adapter is equipped with a plastic washer, be sure it is seated for connection to the CO 2 cylinder.

  • Page 11: Wire Drive Configurations

    8. Install the outer wire guide by aligning it with the pins and tightening the knurled thumbscrews. 9. Close the idle arm and engage the idle roll pressure arm. Adjust the pressure appropriately. CONNECTOR BLOCK SOCKET HEAD CAP SCREW LOOSEN TIGHTEN ACTIV8™...

  • Page 12: Pressure Arm Adjustment

    Excessive brake force may cause motor thermal over- loads or welding problems. FIGURE A.2 WIRE REEL SPINDLE MOUNTING TABS WING NUT ACTIV8™...

  • Page 13: Gun Connection

    • Do not operate with covers, panels or guards removed or open. • Only qualified personnel should perform mainte- nance work. ------------------------------------------------------------------------ The ACTIV8™ comes with a K1500-2 gun adapter installed. (See Figure A.3) To install a gun, 1. Turn power OFF. 2. Remove the thumb screw.

  • Page 14: Power Source To Activ8™ Cable Connection Diagrams

    INSTALLATION POWER SOURCE TO ACTIV8™ CABLE CONNECTION DIAGRAMS ACROSS THE ARC SET-UPS CC Power Sources with Output Terminals Always Hot (See Figure A.4) FIGURE A.4 CC Power Source Classics Big Red’s Eagle 10,000 Plus Pipeliner 200D Without Wire Feed module ACTIV8™...
  • Page 15 RANGER 250, 250 LPG FIGURE A.6 RANGER 305G, 305D RANGER 10,000 RANGER 3 PHASE RANGER225, 225 GXT COMMANDER 300 ACTIV8™ Electrode VANTAGE 300, 400, 500 AIR VANTAGE 500 Work clip Work Place CV/CC switch in the feeder in the "CV" position.
  • Page 16 INSTALLATION CV Power Source with Twist-Mate Connectors and no Remote/Local Switch. (See Figure A.8) FIGURE A.8 Jump er CV-250 CV-300 ACTIV8™ Electrode Wor k clip Work Description K2999-1 ACTIV8™ Place CV/CC switch in the feeder in the "CV" position. KP1696-XX...

  • Page 17: Procedure To Install Conduit Bushing For The Wire Feeder Unit

    4. Install the new conduit bushing, flex tube and thumb screw into the wire feed head. 5. Tighten the set screw. CONDUIT BUSHING (PART OF K1546-2, INCOMING BUSHING KIT) THUMB SCREW (PART OF K1546-2, INCOMING BUSHING KIT) WIRE FEED HEAD FLEX TUBE (T10642-325) SET SCREW FIG 2 A.01 M22832 ACTIV8™...

  • Page 18: Operation

    • Insulate yourself from work and ground. • Always wear dry insulating gloves. • The serviceability of a product or structure uti- lizing the ACTIV8™ wire feeder is and must be NEGATIVE OUTPUT the sole responsibility of the builder/user. Many...

  • Page 19: Duty Cycle

    OPERATION PRODUCT DESCRIPTION RECOMMENDED PROCESSES The ACTIV8™ is a portable feeder for 15 lbs. / 8 in. spools specifically designed for shipyard (shipbuilding and offshore structure fabrication). This wire feeder The ACTIV8™ wire drive feeds electrode for various will offer excellent feeding and welding performance processes as follows:(See Table B.1)

  • Page 20: Case Front Controls

    Wire Feed Speed when in the CC mode. 2. TRIGGER CONNECTOR There is one circular connector for the gun trigger on the front of the ACTIV8™. Note – if the gun trigger is already depressed when the feeder is powered up, the feeder will not activate. Release and then press the gun trigger to begin welding.

  • Page 21: Internal Controls

    WFS knob. Cold feeding, or "cold feeds wire for welding. The inching" the electrode is useful for threading the power source and wire e l e c t r o d e feeder continue welding through until the trigger is released. gun. FIGURE B.2 ACTIV8™...

  • Page 22: Rear Controls

    A steady arc voltage is regulated by the power source by adjusting the arc current. 5. SPOOL RETAINER* 6. SPOOL BRAKE* 7. GUN BUSHING, THUMB SCREW AND SOCKET HEAD CAP SCREW* 8. DRIVE ROLLS AND WIRE GUIDES* (See “Installation Section” for functions.) ACTIV8™...

  • Page 23: Constant Current Operation

    To preset the wire feed speed on CC power sources: The serviceability of a product or structure utiliz- ing the ACTIV8™ wire feeder is and must be the 1. Set the Wire Feed Mode switch inside the sole responsibility of the builder/user. Many vari- ACTIV8™...
  • Page 24 Welding is sometimes performed using constant current For these reasons, Lincoln Electric does NOT recom- power sources. The operation can be more convenient mend constant current semiautomatic welding for...

  • Page 25: Making A Weld

    OPERATION MAKING A WELD The serviceability of a product or structure utilizing the ACTIV8™ wire feeder is and must be the sole respon- sibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the ACTIV8™ wire feeder.

  • Page 26: Accessories

    KP1696-1 KP1696-2 .040" (1.0mm) Cored Wires: .030 -.035" (0.8 - 0.9mm) KP1697-035C Includes: 2 Knurled KP1697-045C .040 -.045" (1.0 - 1.2mm) drive rolls and inner .052" (1.4mm) KP1697-052C wire guide. 1/16" (1.6mm) KP1697-1/16C KP1697-068 .068" (1.7mm) 5/64" (2.0mm) KP1697-5/64 ACTIV8™...
  • Page 27 Cable of length "xx" for lengths up to 60' (18.3m). Lug to Lug, 4/0 Cable of length "xx" for lengths greater than 60' (18.3m). KP3103-1 Shielding Gas Filter Includes one in-line shielding gas filter. K3156-1 Flow Meter Kit Includes one in-line flow meter assembly. ACTIV8™...
  • Page 28 NOTE: T10642-325 Flex Tube Required with K1546-2 K586-1 Deluxe Adjustable Gas Regulator. Includes: Deluxe Gas Regulator for Mixed Gases, Adapter for CO and 10' (3.0m) Hose. K283 Wire Feed Speed Meter Includes: A wire feed speed meter with digital display. ACTIV8™...

  • Page 29: Maintenance

    Check weld cables, control cables and gas hoses for cuts. PERIODIC MAINTENANCE • Replace the drive rolls and inner wire guide when they are worn. • Blow out or vacuum the inside of the feeder. ACTIV8™...

  • Page 30: Calibration Specification

    11. Measure WFS. If reading is 795 to 805 IPM cali- bration is complete. If not, insert shorting plug into 3. Connect the ACTIV8™ to the constant voltage DC Control PC Board J3, and adjust WFS knob to 795 power supply capable of supply at least 9 amps or to 805 IPM and then remove the shorting plug.

  • Page 31: 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 32 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 or 5. Replace the contact tip. has spatter. 6. Verify the proper parts are installed.
  • Page 33 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. ACTIV8™...
  • Page 34 DIAGRAMS ACTIV8™...
  • Page 35 DIMENSION PRINT ACTIV8™...
  • Page 36 NOTES ACTIV8™...
  • Page 37 P-677 P-677 PARTS LIST FOR ACTIV8 ™ ACTIV8 ™...
  • Page 38 P-677-A P-677-A ILLUSTRATION OF SUB-ASSEMBLIES 09-15-2011 ACTIV8 ™...
  • Page 39 P-677-A.1 P-677-A.1 ACTIV8 ™ For Code: 11770, 12198 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.
  • Page 40 1 2 3 4 5 6 7 8 9 DESCRIPTION PART NO. QTY. Inert Arc Nut (Brass) T15007-1 Hose Nipple (Brass) T15008 Flex Tube T10642-325 Ground Lead Assembly S17211-7 05-31-2012 ACTIV8 ™...
  • Page 41 NOTES ACTIV8 ™...
  • Page 42 P-677-C P-677-C Plastic Case Assembly 13A 13B 13B 13C 09-15-2011 ACTIV8 ™...
  • Page 43 Decal (Product Name) (Not Shown) (L16002-10) (Part of L16002) Decal (Product Name) (Not Shown) (L16002-11) (Part of L16002) Warning Decal (Not Shown) S25815 13A Self Drilling Screw S28933-1 13B Lock Washer E106A-1 13C Plain Washer S9262-27 NSS - Not Sold Separately 10-17-2011 ACTIV8 ™...
  • Page 44 P-677-D P-677-D Wire Drive Assembly, Spindle & Miscellaneous 30A 30B 25A 25B 25C 20 31A 31B 6A 6B 6B 6C 10-17-2011 ACTIV8 ™...
  • Page 45 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 ITEM DESCRIPTION PART NO. QTY. Jan-14 ACTIV8 ™...
  • Page 46 Decal, Pressure Arm (L16002-3) (Part of L16002) Decal, Cold Feed/Gas Purge (L16002-5) (Part of L16002) Decal, 2 Step/Trigger Interlock (L16002-6) (Part of L16002) Decal, CV/CC (L16002-7) (Part of L16002) Decal, Panel (L16002-4) (Part of L16002) NSS - Not Sold Separately Oct-13 ACTIV8 ™...
  • Page 47 NOTES ACTIV8 ™...
  • Page 48 P-677-E P-677-E P.C. Boards, Fan & Contactor Assembly 10-17-2011 ACTIV8 ™...
  • Page 49 This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so as to eliminate errors, confusion and updates. Mar-2014 ACTIV8 ™...
  • Page 50 NOTES ACTIV8 ™...
  • Page 51 NOTES ACTIV8™...
  • Page 52 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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