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IM952-A
AutoDrive 4R90
March, 2010
For use with machines having Code Number : 11492, 11722
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. nd,
most importantly, think before you
act and be careful.
OPERATOR'S MANUAL
Copyright © Lincoln Global Inc.
• 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
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Related Manuals for Lincoln Electric AutoDrive 4R90
Summary of Contents for Lincoln Electric AutoDrive 4R90
- Page 1 OPERATOR’S MANUAL Copyright © Lincoln Global Inc. • 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...
- Page 2 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 cancer, birth defects, or other reproductive harm.
- Page 3 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 and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating 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 T T h h a a n n k k Y Y o o u u for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• 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.
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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 Weld Cable Sizes .........................A-2 Coaxial Weld Cable ......................A-3 Wire Drive Cable .........................A-4 Shielding Gas Connection ....................A-5 Wire Drive Configuration ......................A-6 Changing The Gun Receiver Bushing ..................A-6 Procedure to Install Drive Rolls and Wire Guides ..............A-7 Conduit Installation .......................A-8 System Set-Up ........................A-9... -
Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS – AutoDrive 4R90 (K2685-2) INPUT VOLTAGE, CURRENT INPUT VOLTAGE ± 10% INPUT AMPERES 0-40 VDC RATED OUTPUT @ 104°F (40°C) DUTY CYCLE INPUT AMPERES 100% rating GEARING - WIRE FEED SPEED RANGE-WIRE SIZE GMAW FCAW GEARING WIRE SIZES... -
Page 9: Safety Precautions
(61 to 76m) CYCLE 4 or 5 40 & 30 ** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables larger than recommended, or cables rated higher than 167°F(75°C). AutoDrive 4R90... -
Page 10: Coaxial Weld Cable
** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables larger than recommended, or cables rated higher than 167°F(75°C). Power Source Power Source Work Work Electrode Electrode Coaxial Weld Cable Coaxial Weld Cable Electrode Electrode Wire Feeder Wire Feeder Work Work AutoDrive 4R90... -
Page 11: Wire Drive Cable
“2A” Differential Tachometer +15VDC Tech Supply “2B” Differential Tachometer Tachometer Common Reserved Reserved Reserved Reserved “1A” Differential Tachometer “1A” Differential Tachometer “1B” Differential Tachometer “1B” Differential Tachometer Reserved “2B” Differential Tachometer “67” Electrode Sense Lead “67” Electrode Sense Lead AutoDrive 4R90... -
Page 12: Shielding Gas Connection
Note: if connecting to 100% CO 2 cylinder, insert regulator adapter between regulator and cylinder valve. If adapter is equipped with a plastic washer, be sure it is seated for connection to the CO 2 cylinder. AutoDrive 4R90... -
Page 13: Wire Drive Configuration
2. Remove the welding wire from the wire drive. 3. Remove the thumb screw from the wire drive. 4. Remove the welding gun from the wire drive. FIGURE A.2 SOCKET HEAD CAP SCREW GUN RECEIVER BUSHING CONNECTOR BLOCK THUMB SCREW LOOSEN TIGHTEN AutoDrive 4R90... -
Page 14: Procedure To Install Drive Rolls And Wire Guides
6. Rotate all of the triangular rings to the locked posi- tion. 3. Rotate all of the triangular rings to the unlocked position. 7. Assemble the outer wire guide. 8. Adjust the pressure arms to the recommended setting. AutoDrive 4R90... -
Page 15: Conduit Installation
To install conduit to the wire drive: 1. Slide the conduit bushing into the feed plate and secure with the set screw. 2. Slide the conduit into the bushing and lock in place with the thumb screw. SCREW THUMB SCREW CONDUIT BUSHING CONDUIT AutoDrive 4R90... -
Page 16: System Set-Up
INSTALLATION SYSTEM SET-UP NEW ARMS SYSTEM SET-UP (SINGLE NEW ARMS) AutoDrive 4R90... -
Page 17: Operation
ARC RAYS can burn. • Wear eye, ear and body protec- tion. --------------------------------------------------------------------- OUTPUT CURRENT SEE ADDITIONAL WARNING INFORMATION UNDER ARC WELDING SAFETY PRECAUTIONS AND IN THE FRONT OF THIS OPERATING MAN- PROTECTIVE UAL. GROUND ---------------------------------------------------------------------- WARNING OR CAUTION AutoDrive 4R90... -
Page 18: Definition Of Welding Terms
ß • Mounts only to FANUC ArcMate100iC arms. General Physical Description RECOMMENDED POWER SOURCES The AutoDrive 4R90 wire feeders are powerful yet compact wire drives for robotic and hard automation ß • Power Wave 355M (requires wire drive board) applications. - Page 19 .045 (1.2mm) Includes: 4 Knurled Cored Wires: KP1505-035C .030-.035" (0.8-0.9mm) drive rolls and inner KP1505-045C .040-.045" (1.0-1.2mm) wire guide. Includes: 4 polished Aluminum Wires: KP1507-3/64A 3/64" (1.2mm) U groove drive rolls, outer wire guide and inner wire guide. AutoDrive 4R90...
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Page 20: Accessories
Fast-Mate guns.) with trigger connector. K515-xx Wire Conduit Requires K1546-1 K565-xx Wire Conduit Requires K1546-1 Incoming Bushing, for Lincoln K1546-1 Conduit .025- 1/16" (0.6 - 1.6mm) Includes: Incoming bushing and wire. Compatible with Electron hex key wrench. Beam Conduit. AutoDrive 4R90... - Page 21 Includes: 1 cable of length “xx” K1796-xx Coaxial Cables feet. 14 pin connectors on both ends. Cable length can- not be extended by connecting K1785 cables together. K1785-xx Wire Drive Cables K1733-1 Wire Straightener K590-6 Water Connection Kit AutoDrive 4R90...
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Page 22: Maintenance
• Only qualified personnel should perform main- tenance work. ---------------------------------------------------------------------- ROUTINE MAINTENANCE To remove the AutoDrive 4R90 for servicing: (See Figure D.1) PERIODIC MAINTENANCE 1. Turn off power to the welding power supply and the entire weld cell. -
Page 23: Troubleshooting
• Only qualified personnel should perform maintenance work. 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. AutoDrive 4R90... - Page 24 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. AutoDrive 4R90...
- Page 25 5. Reduce the pressure arm setting. 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. AutoDrive 4R90...
- Page 26 DIAGRAMS Enhanced Diagram AutoDrive 4R90...
- Page 27 DIMENSION PRINT " " " AutoDrive 4R90...
- Page 28 NOTES AutoDrive 4R90...
- Page 29 NOTES AutoDrive 4R90...
- Page 30 NOTES AutoDrive 4R90...
- Page 31 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 bajo carga con la piel o ropa moja-...
- Page 32 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 33 • 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...