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Operator's Manual
ACTIVE8
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10085-A
| Issue Date Mar-14
© 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 ACTIVE8
- Page 1 Operator’s Manual ACTIVE8 ™ 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 Mar-14...
- Page 2 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 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 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.
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Page 7: Table Of Contents
viii viii TABLE OF CONTENTS Page Installation........................Section A Technical Specifications .......................A-1 Safety Precautions .......................A-2 Location ..........................A-2 High Frequency Protection ....................A-2 Weld Cable Sizes .........................A-2 Trigger Connector ........................A-3 Shielding Gas Connection ....................A-3 Wire Drive Configurations ....................A-4 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... -
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
INSTALLATION 4. Attach the flow regulator to the cylinder valve and TRIGGER CONNECTOR tighten the union nut(s) securely with a wrench. Note: if connecting to 100% CO 2 cylinder, insert regulator There is one circular connector for the gun trigger on adapter between regulator and cylinder valve. -
Page 11: Wire Drive Configurations
INSTALLATION WIRE DRIVE CONFIGURATION 8. Connect the shielding gas hose to the new gun bushing, if required. (See Figure A.1) 9. Rotate the gun bushing until the thumb screw hole CHANGING RECEIVER aligns with the thumb screw hole in the feedplate. BUSHING Slide the gun receiver bushing into the wire drive and verify the thumb screw holes are aligned. -
Page 12: Pressure Arm Adjustment
INSTALLATION PRESSURE ARM ADJUSTMENT LOADING SPOOLS OF WIRE WARNING WARNING ELECTRIC SHOCK can kill. • Keep hands, hair, clothing and tools away from rotating equipment. • Turn the input power OFF at the weld- ing power source before installation or •... -
Page 13: Gun Connection
INSTALLATION GUN CONNECTION WARNING ELECTRIC SHOCK can kill. • Turn the input power OFF at the weld- ing power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot"... -
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 INSTALLATION CV Power Sources with Stud Connectors and no Remote/Local Switch(See Figure A.6) 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"...
- 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 Drive Roll Kit KP1697-XX See Magnum Literature...
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Page 17: Procedure To Install Conduit Bushing For The Wire Feeder Unit
A-10 A-10 INSTALLATION PROCEDURE TO INSTALL CONDUIT BUSHING FOR THE WIRE FEEDER UNIT WARNING Turn off the Welding Power Source before installing or changing drive rolls and / or guides. When inching with gun trigger, electrode and drive mechanism are "hot" to work and ground. ELECTRIC SHOCK Only qualified persons should install, use or service this machine. -
Page 18: Operation
OPERATION SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. WARNING INPUT POWER • 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 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) with hard and soft shell welding wires. -
Page 20: Case Front Controls
Polarity LED gun. Always use quality electrode, such as L-50 or L-56 from Lincoln Electric. 1. WIRE FEED SPEED KNOB Use the Wire Feed Speed Knob to adjust the rate 5. POLARITY LED of wire feed speed. -
Page 21: Internal Controls
OPERATION When gas purging the gas solenoid valve will INTERNAL CONTROLS (See Figure B.2) energize but neither the power source output nor the drive motor will be turned on. The Gas Purge switch is useful for setting the proper flow rate of ITEM DESCRIPTION shielding gas. -
Page 22: Rear Controls
OPERATION Trigger Interlock REAR CONTROLS (See Figure B.3) Trigger Interlock operation provides for operator comfort when making long welds. When the gun ITEM DESCRIPTION trigger is first pulled, the welding power source energizes the output and the wire feeder feeds Shielding Gas Inlet with gas filter wire for welding. -
Page 23: Constant Current Operation
1. Set the Wire Feed Mode switch inside the sole responsibility of the builder/user. Many vari- ACTIV8™ to "CC". ables beyond the control of The Lincoln Electric 2. Refer to the Figure B.4 graph to determine cc set- Company affect the results obtained in using the ting of the wire feed speed knob. - 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...
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Page 25: Making A Weld
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. These variables include, but are not limited to, welding... -
Page 26: Accessories
ACCESSORIES OPTIONAL KITS AND ACCESSORIES DRIVE ROLL KITS, 2 ROLL DRIVE WIRE TYPE ELECTRODE SIZE KP KIT Steel Wires: .023 -.030" (0.6 - 0.8mm) KP1696-030S Includes: 2 V groove .035" (0.9mm) KP1696-035S drive rolls and inner KP1696-045S .045" (1.2mm) .052" (1.4mm) KP1696-052S wire guide. - Page 27 ACCESSORIES K3061-1 Plastic Case Includes: a complete engi- neered plastic case. Includes: Twist-Mate to Lug 2/0 cable K1803-1 Work and Feeder Cables Package. 14' (1.2m) long with Ground Clamp, and Twist-Mate to Lug 2/0 Cable 9' (2.7m) long. Includes: Twist-Mate to Lug, K1840-xx Weld Power Cable, Twist-Mate to Lug.
- Page 28 ACCESSORIES Includes: 14 pin circular connector with jumper for Jumper Plug Kit K484 leads 2-4. For use in power sources for turning the weld terminals "ON" at all times. K910-1 Ground Clamp Includes: One 300 Amp Ground Clamp. K910-2 Ground Clamp Includes: One 500 Amp Ground Clamp.
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Page 29: 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 30: Calibration Specification
MAINTENANCE CALIBRATION SPECIFICATION 7. Measure WFS. If reading is 49 to 51 IPM, proceed to step 8. If not unplug J3, insert shorting plug into Calibration of the ACTIV8™ may be required when Control PC Board J3 (shorts pins 4 & 8), and adjust the p.c. -
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 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION 1. Replace the motor and tachome- Wire feed speed consistently oper- 1. The brushes on the motor are ates at the wrong value. The speed worn.
- Page 34 DIAGRAMS ACTIV8™...
- Page 35 DIMENSION PRINT ACTIV8™...
- Page 36 NOTES ACTIV8™...
- Page 37 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.