Lincoln Electric DLF-82 Operator's Manual
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Lincoln Electric DLF-82 Operator's Manual

Lincoln Electric DLF-82 Operator's Manual

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Operator's Manual
DLF-82
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10631
| Issue D ate Mar - 24
© Lincoln Global, Inc. All Rights Reserved.
®
For use with machines having Code Numbers:
13240, 13241, 13242
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric DLF-82

  • Page 1 Operator’s Manual DLF-82 ® For use with machines having Code Numbers: 13240, 13241, 13242 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...

  • Page 3: Section A: Warnings

    P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2. A Free copy of “Arc Welding Safety” booklet E205 2.a. Electric current owing through any conductor is available from the Lincoln Electric Company, 22801 causes localized Electric and Magnetic Fields (EMF). St. Clair Avenue, Cleveland, Ohio 44117-1199.

  • Page 4: Electric Shock Can Kill

    SAFETY 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 SAFETY 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 welding sparks the gas and pressure used.
  • Page 6 TABLE OF CONTENTS DLF-82 ®...
  • Page 7 • Cold-feed button for wire feeding without activating welding • The heart of the DLF-82 is the 2 roll MAXTRAC® drive. The output. patented features on the wire drive offer tool-less changing of the drive rolls and wire guides for quick spool changes. A •...

  • Page 8: Installation

    SELECT SUITABLE LOCATION For best wire feeding performance, place the DLF-82 on a stable and dry surface. Keep the wire feeder in a vertical position. Do not operate the wire feeder on an angled surface of more than 15 degrees.

  • Page 9: Technical Specifications

    Description Meters Included Installed DLF-82 K5282-1 DIGITAL K3345-1 .035/.045 K5282-2 K3345-1 DLF-82 with wire reel stand DIGITAL Solid Wire DLF-82 with wire reel .035/.045 K5282-3 K3345-1 DIGITAL stand and gun Solid Wire INPUT - SINGLE PHASE Input Amperes @ Rated...

  • Page 10: Trigger Connector

    Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable drop. TRIGGER CONNECTOR There is one circular connector for the gun trigger on the front of the DLF-82. Picture Function Wiring GUN TRIGGER SWITCH SUPPLY...
  • Page 11 DLF-82 ® INSTALLATION PROCEDURE TO INSTALL DRIVE ROLLS AND PRESSURE ARM ADJUSTMENT WIRE GUIDES WARNING WARNING ELECTRIC SHOCK CAN KILL. ELECTRIC SHOCK CAN KILL. • Turn the input power OFF at the welding • Turn the input power OFF at the welding power source power source before installation or before installation or changing drive rolls and/or guides.
  • Page 12 DLF-82 ® INSTALLATION CHANGING THE GUN ADAPTER BUSHING WARNING ELECTRIC SHOCK CAN KILL. • Turn the input power OFF at the welding power source before installation or changing drive rolls and/or guides. • Do not touch electrically live parts. •...

  • Page 13: Shielding Gas Connection

    • Shut off shielding gas supply when not in use. The DLF-82 comes with an adapter installed, that accepts #2 - • See American National Standard #4 guns. To install a gun: Z-49.1, "Safety in Welding and Cutting”...

  • Page 14: Operation

    The available clothing. range of the DLF-82 wirefeeder may not be suitable for all • Insulate yourself from work and applications, and the builder/user is and must be solely ground.
  • Page 15 DLF-82 ® INSTALLATION Item K# Description TYPICAL SET-UP WITH ARCLINK® (RECOMMENDED) K5282-1 DLF-82 Place the power source in ArcLink® Mode. K3607-2 Flextec 500X Multi-Process Welder Drive Roll Kit KP1696-1 Magnum Pro Curve HDE 350 K4532-2-10-45 Work Cable K2484-2...

  • Page 16: Definition Of Welding Terms

    DLF-82 ® OPERATION DEFINITION OF WELDING TERMS NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process vari- ables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control.
  • Page 17 DLF-82 ® PRESET VOLTAGE DISPLAY IN SYNERGIC WELDING While Idle: For synergic CV modes, the right display will show volts. When the right knob is rotated, the display will show an upper The left display shows the preset wire feed speed. The right or lower bar if the voltage is above or below the ideal voltage display shows the preset voltage or the preset trim.

  • Page 18: Steel And Stainless Synergic Gmaw-P (Pulsed Mig) Welding

    DLF-82 ® OPERATION STEEL AND STAINLESS SYNERGIC GMAW-P (PULSED MIG) WELDING Synergic GMAW-P (Pulsed MIG) welding is ideal for low spatter, out of position and reduced heat input applications. During pulse welding, the welding current continuously switches from a low level to a high level and then back again. Each pulse sends a small droplet of molten metal from the wire to the weld puddle.
  • Page 19 The display continues to hold the value of the amperage display shows the preset voltage or trim when it is connected to a power source that supports the DLF-82 (see Figure B.1). It will display dashes when connected to an incompatible power source completion of each weld.
  • Page 20 Pressing the bottom right pushbutton allows you to cycle through and make active any of the 4 memories stored in the DLF-82. allows the user to search through a hierarchy of data in the...
  • Page 21 DLF-82 ® Run-in Speed (% of weld WFS) There are 3 levels of menus that can be accessed on the DLF-82: Run-in speed is used to modify the wire feed speed during the process-related settings, feeder settings, and advanced settings.
  • Page 22 Starting Procedure Starting procedure has a factory default setting of Auto. If desired, a custom starting routine can be set. If active, the DLF-82 will strike the arc with the set WFS and Voltage and then ramp over the set amount of time to the welding WFS and Voltage.
  • Page 23 DLF-82 OPERATION ® Arc Current or Actual WFS during welding: Setup Menu With "Display" selected (blinking) in the Setup Menu, pressing The Setup Menu is the last item choice in the Settings Menu. the bottom encoder push button will allow the top left digital When “Enter Setup Menu”...
  • Page 24 DLF-82 ® OPERATION Memory Save Enable: Setting Volts or Trim Limits: This setting allows for the ability to save/overwrite new memories. With Volts Limits selected (blinking) in the Setup Menu, pressing It is enabled by default and can be disabled by navigating to the bottom knob will cycle through the Low Limits (LO) and High Limits (HI).
  • Page 25 Pushing the bottom encoder will scroll through the different software revisions of different printed circuit boards in the system. - WD/UI contains information about the DLF-82's Control Board. - WCtl contains information about the Power Source's Control/Switch boards.

  • Page 26: Case Front Controls

    Gas Purge Button/4 Step Button - Push and hold for 0.5 second Wire Feed Speed Digital Display - The DLF-82 has a digital to close the gas solenoid, allowing shielding gas to ow and release display that shows the wire feed speed. This display is also to open the solenoid.

  • Page 27: Internal Connections

    DLF-82 ® OPERATION INTERNAL CONNECTIONS 1. Pressure Arm Adjustment Knob 2. Spool Retainer 3. Spindle Brake 4. Gun Bushing 5. Thumb Screw 6. Hex Head Set Screw 7. Drive Hubs 8. Inlet Wire Guide B-14...

  • Page 28: Rear Connections

    CAUTION REAR CONNECTIONS The serviceability of a product or structure utilizing the DLF-82 wire feeder is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the DLF-82 wire feeder.
  • Page 29 DLF-82 ® ACCESSORIES OPTIONS/ACCESSORIES The following options/accessories are available for your DLF-82 from your local Lincoln Electric Distributor. DRIVE ROLL KITS, 2 ROLL DRIVE Steel Wire Drive Roll Kits KP1696-030S .023-.030 (0.6-0.8MM) KP1696-035S .035 (0.9MM) KP1696-045S .045 (1.2MM) INCLUDES: KP1696-052S .052 (1.4MM)
  • Page 30 DLF-82 ® ACCESSORIES Optional Kits & Accessories K910-1 & K910-2 Work Clamp Jaws open full 2-1/2 inches (63 mm). Welding cable lug bolts K2485-2 Weld Cable Tweco Male to Tweco Female (2/0), 50ft. directly to the work clamp. 60% K2485-3 Weld Cable Tweco Male to Tweco Female (3/0), 50ft.

  • Page 31: Routine Maintenance

    DLF-82 ® MAINTENANCE MAINTENANCE WARNING ELECTRIC SHOCK CAN KILL. • Turn the input power OFF at the welding 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 32: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING 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 33 DLF-82 ® TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION PROBLEM Err 82 Motor overload, long The wire drive motor has 1. Check that the electrode slides easily through the gun and cable.
  • Page 34 DLF-82 ® TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION PROBLEM Inconsistent wire feeding or 6. Improper gun liner, tip, drive 6. Verify the proper parts are installed. wire not feeding but drive rolls and/or inner wire 7.
  • Page 35 DLF-82 ® DIAGRAMS...
  • Page 36 DLF-82 ® DIAGRAMS...
  • Page 37 This page intentionally left blank...
  • Page 38 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 39 WARNING 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. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 40 Lincoln Electric is a responsive manufacturer, but the de nition of speci cations, and the selection and use of speci c products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

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