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Lincoln Electric Activ8X Operator's Manual
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Lincoln Electric Activ8X Operator's Manual

For use with machines having code numbers: 12759, 12877
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Operator's Manual
Activ8X
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10458-A
| Issue D ate Apr-19
© Lincoln Global, Inc. All Rights Reserved.
™
For use with machines having Code Numbers:
12759, 12877

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Summary of Contents for Lincoln Electric Activ8X

  • Page 1 Operator’s Manual Activ8X ™ For use with machines having Code Numbers: 12759, 12877 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) IM10458-A | Issue D ate Apr-19...
  • 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 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 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 ACTIV8X™...
  • Page 7 Tweco-compatible style #2-#4 gun adapter. Other K1500 series gun adapters are available as field installed options. • Vantage 322, 435, 549, 565 In addition to CrossLinc, the Activ8X wire feeder has the following • Air Vantage 566 features: • Dual Vantage 700 •...
  • Page 8 ACTIV8X™ INSTALLATION tecHnical speciFications - MODEL SUMMARY Drive Roll Kit Feed Plate Gun Adapter Description Meters Included Installed K3519-1 ACTIV8X™ DIGITAL ---- K1500-2 K3519-2 ACTIV8X™ DIGITAL ---- K1500-2 INPUT - SINGLE PHASE Input Amperes @ Rated Input Voltage +/- 10%...
  • Page 9 Do not operate the wire feeder on an angled surface of more than 15 degrees. Do not submerge the Activ8X™. The Activ8X™ is rated IP23 and is suitable for outdoor use. The handle of the Activ8X™ is intended for moving the wire feeder about the work place only.
  • Page 10 Description (recoMMenDeD) K3519-1 Activ8X™ (Tweco) K3519-2 Activ8X™ CE (Twistmate/Dinse) Place the power source Local/Remote switch in the Remote position. In many newer models of CrossLinc compatible power Drive Roll Kit sources, the Local/Remote switch is automatically overridden by Welding Gun CrossLinc and there is no need to set it.
  • Page 11 INSTALLATION CV Power Sources with Stud Connectors and no Remote/Local Switch Item Description K3519-1 Activ8X™ (Tweco) K3519-2 Activ8X™ CE (Twistmate/Dinse) Drive Roll Kit Welding Gun CV power source Weld Power Cable Work Cable w/Clamp Lug to Tweco Adapter Ranger 250...
  • Page 12 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 Activ8X™ Picture Function Wiring 15 VOLT SUPPLY...
  • Page 13 ACTIV8X™ 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. • When inching with the gun trigger, electrode and drive mechanism are "hot"...
  • Page 14 ACTIV8X™ 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 15 • Shut off shielding gas supply when not in use. The Activ8X™ comes with a K1500-2 gun adapter installed, this • See American National Standard accepts #2 - #4 guns. To install a gun, Z-49.1, "Safety in Welding and Cutting”...
  • Page 16 Observe additional Safety Guidelines detailed in the beginning of this manual. SAFETY PRECAUTIONS The serviceability of a product or structure utilizing the Activ8X™ wirefeeder is and must be the sole responsibility of the WARNING builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in using the ELECTRIC SHOCK can kill.
  • Page 17 8. Amperage LED - When the Amperage LED is illuminated, amperage is being displayed. 1. Wire Feed Speed Digital Display - The Activ8X™ has a digital 9. Voltage LED - The Voltage LED will be illuminated when the display that shows the wire feed speed. This display is also Voltage Digital Display is displaying actual voltage or when its capable of displaying amperage and the setup menu.
  • Page 18 ACTIV8X™ OPERATION internal controls 10. 2 Step - Trigger Interlock Switch - The 2 Step - Trigger 1. Pressure Arm Adjustment Knob Interlock switch changes the function of the gun trigger. 2 2. Spool Retainer Step trigger operation turns welding on and off in direct response to the trigger.
  • Page 19 CAUTION rear controls The serviceability of a product or structure utilizing the Activ8X™ 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 Activ8X™...
  • Page 20 ACTIV8X™ OPERATION DiGital Meter operation During Welding The value in the left display will be either amps or actual wire feed CrossLinc™ speed, depending upon the selection chosen in the set-up menu. When connected to a power source that supports CrossLinc™, the The corresponding LED below the display will light.
  • Page 21 MenU operation The left display will show the menu item, and the right display will The Activ8X™ setup menu is accessed through the hidden setup show the set value. menu push button that is located below a small hole just right of the right 4 digit display.
  • Page 22 LInC only when CrossLinc™ is on. By default, CrossLinc is active and it is assumed the Activ8X is being used with a CV output power source. In this case, voltage will be presettable at the feeder and WFS will be the...
  • Page 23 ACTIV8X™ OPERATION Left Right Factory Setup Menu Item Description Display Display Default This is used to calibrate the wfs meter to a known calibrated wfs meter. To calibrate the wire feed speed, before entering the set-up menu: • Set the display to the desired wire feed speed...
  • Page 24 4. Determine the vertical line representing the CC Wire Feed Speed setting where the above two lines cross. (See Figure B.4 arrow line for 450.) Set the Activ8X™ wire feed speed knob to this value. CC WFS dial setting = desired WFS x 35...
  • Page 25 CAUTION when such welds are made under constant current operation. For these reasons, Lincoln Electric does NOT recommend constant Lincoln Electric does NOT recommend constant current current semiautomatic welding for applications which need to...
  • Page 26 ACTIV8X™ ACCESSORIES OPTIONS/ACCESSORIES The following options/accessories are available for your Activ8X™ 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) 2 V GROOVE DRIVE ROLLS AND INNER WIRE GUIDE.
  • Page 27 ACTIV8X™ ACCESSORIES K910-1 & K910-2 Optional Kits & Accessories 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 28 ACTIV8X™ 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 29 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 30 ACTIV8X™ TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEM POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Err 81 Motor overload, long The wire drive motor has 1. Check that the electrode slides easily through the gun and cable. term overheated.
  • Page 31 ACTIV8X™ 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 32 ACTIV8X™ DIAGRAMS...
  • Page 33 ACTIV8X™ DIAGRAMS...
  • Page 34 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 35 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 36 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.