Lincoln Electric PIPEFAB Series Operator's Manual
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Lincoln Electric PIPEFAB Series Operator's Manual

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Operator's Manual
PIPEFAB
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www.lincolnelectric.com/registration
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Date Purchased
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IM10549
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© Lincoln Global, Inc. All Rights Reserved.
WELDING SYSTEM
™
Jul - 20
For use with machines having Code Numbers:
POWER SOURCE: 12858, 13010
FEEDER: 12929
REMOTE UI: 12938
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 PIPEFAB Series

  • Page 1 Operator’s Manual PIPEFAB WELDING SYSTEM ™ For use with machines having Code Numbers: POWER SOURCE: 12858, 13010 FEEDER: 12929 REMOTE UI: 12938 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/registration Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon.
  • 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. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 2.d. All welders should use the following procedures in order to 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 PRÉCAUTIONS DE SÛRETÉ 5. Toujours porter des lunettes de sécurité dans la zone de Pour votre propre protection lire et observer toutes les instruc- soudage. Utiliser des lunettes avec écrans lateraux dans les tions et les précautions de sûreté specifiques qui parraissent zones où...
  • Page 7 EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric methods of reduCIng emIssIons equipment. It is designed for industrial and professional use.

  • Page 8: Table Of Contents

    TABLE OF CONTENTS PRODUCT DESCRIPTION…………………………………………………………………………………………………1 PRODUCT LISTING…………………………………………………………………………………………………………1 RECOMMENDED PROCESSES AND EQUIPMENT…………………………………………………………………...1 TECHNICAL SPECIFICATIONS…………………………………………………………………………………………...4 INSTALLATION................................SECTION A SELECT SUITABLE LOCATION............................A-2 LIFTING ................................A-2 STACKING ................................A-2 TILTING ................................A-2 MECHANICAL INSTALLATION............................A-4 STANDARD (BENCH) CONFIGURATION ........................A-4 INSTALLING DRIVE ROLLS............................A-7 WIRE DRIVE PRESSURE SETTING............................A-8 LINCOLN, STANDARD #2-#4, STANDARD #5, MILLER GUN ADAPTER INSTALLATION ..........
  • Page 9 TABLE OF CONTENTS MAINTENANCE ................................SECTION D ROUTINE MAINTENANCE............................D-1 PERIODIC MAINTENANCE............................D-1 CALIBRATION SPECIFICATION............................ D-2 WIRING DIAGRAM AND DIMENSION PRINT ......................SECTION E PARTS LIST ........................PARTS.LINCOLNELECTRIC.COM Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

  • Page 10: Product Description

    Superior arc performance, simplicity, and flexibility are at the core of the PipeFab™. Being an advanced so�ware controlled system, the PipeFab™ is readily user updateable with free so�ware from www.powerwaveso�ware.com allowing it to take advantage of the latest and greatest innova�ons from Lincoln Electric’s welding technologies. PRODUCT LISTING K NUMBER PRODUCT NAME K3731-1 PIPEFAB™...
  • Page 11 PIPEFAB™ WELDING SYSTEM PRODUCT DESCRIPTION RECOMMENDED EQUIPMENT The PipeFab™ Power Source and PipeFab™ Feeder make one cohesive unit that must be paired · together. PROCESS LIMITATIONS Processes must be within the duty cycle and rating of the power source and wire feeder. See ·...
  • Page 12 PIPEFAB™ WELDING SYSTEM PRODUCT DESCRIPTION FEEDER Standard bench can be converted to boom configuration and automatic oscillators. · The feed plates can be rotated to accommodate different gun angles. · · Uses 5 pin K1543-xx or K2683-xx ArcLink cables. Cables may be joined together to make longer lengths.

  • Page 13: Technical Specifications

    PIPEFAB™ WELDING SYSTEM PRODUCT DESCRIPTION TECHNICAL SPECIFICATIONS PIPEFAB™ (K3731-1, K3732-1, K3734-1, K3735-1) POWER SOURCE - INPUT VOLTAGE AND CURRENT POWER INPUT VOLTAGE INPUT FACTOR @ MODEL DUTY CYCLE IDLE POWER ±10% AMPERES RATED OUTPUT K3731- 208/230/400*/460/5 550 WATTS 100% 53/46/26/24 50/60 HZ MAX.
  • Page 14 PIPEFAB™ WELDING SYSTEM PRODUCT DESCRIPTION RECOMMENDED INPUT WIRE AND FUSE SIZES TIME DELAY FUSE OR CORD SIZE INPUT VOLTAGE / EFFECTIVE INPUT AMPERE BREAKER PHASE / FREQUENCY RATING AND DUTY CYCLE AWG SIZES (MM AMPERAGE 200-208/3/50/60 53A, 100% 4 (25) 230/3/50/60 46A, 100% 4 (25)
  • Page 15 PIPEFAB™ WELDING SYSTEM PRODUCT DESCRIPTION WELDING PROCESS PROCESS OUTPUT RANGE (AMPERES) MEAN OCV (UO) GMAW GMAW-P 40-400 A 73 V FCAW GTAW-DC 5-400 A 36 V SMAW 55-400 A 63 V PHYSICAL DIMENSIONS MODEL HEIGHT WIDTH DEPTH WEIGHT 30 IN 17.5 IN 34.8 IN 340 LBS.

  • Page 16: Installation

    PIPEFAB™ WELDING SYSTEM INSTALLATION INSTALLATION ELECTRIC SHOCK can kill. Turn the input power OFF at the disconnect switch or fuse box · before attempting to connect or disconnect input power lines, output cables or control cables. Only qualified personnel should perform this installation. ·...

  • Page 17: Select Suitable Location

    PIPEFAB™ WELDING SYSTEM INSTALLATION SAFETY PRECAUTIONS Read this entire installation section before operating machine. SELECT SUITABLE LOCATION The PipeFab™ will operate in harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life and reliable operation. ·...
  • Page 18 PIPEFAB™ WELDING SYSTEM INSTALLATION FIGURE A.1...

  • Page 19: Mechanical Installation

    PIPEFAB™ WELDING SYSTEM INSTALLATION MECHANICAL INSTALLATION All accessory kits such as the PipeFab™ Undercarriage Kit and PipeFab™ Cooler come with installation instructions. Consult these installation instructions before assembly. STANDARD (BENCH) CONFIGURATION The PipeFab™ Feeder is installed on the PipeFab™ Power Source as shown in the steps below. The installation is the same whether or not the power source has the water cooler installed.
  • Page 20 PIPEFAB™ WELDING SYSTEM INSTALLATION FIGURE A.3 3. Position the PipeFab™ Feeder onto the Wire Reel Stand. For secure mounting, ensure the feet of the feeder engage with the feet cutouts in the Wire Reel Stand. FIGURE A.4 4. If desired, the PipeFab™ feeder and cable management brackets can be hard mounted to the wire reel stand using the provided hardware and L brackets as shown below.
  • Page 21 PIPEFAB™ WELDING SYSTEM INSTALLATION FIGURE A.5 - L BRACKET INSTALLATION FIGURE A.6 - CABLE MANAGEMENT BRACKET MOUNTING...

  • Page 22: Installing Drive Rolls

    PIPEFAB™ WELDING SYSTEM INSTALLATION INSTALLING DRIVE ROLLS FIGURE A.7 1. Turn power OFF at the welding power source. 2. Open the wire drive door by pulling on the top. 3. Remove the outer wire guide. 4. Remove drive rolls by pulling straight out. It may be necessary to wiggle the drive roll to free it from the snap ring.

  • Page 23: Wire Drive Pressure Setting

    PIPEFAB™ WELDING SYSTEM INSTALLATION WIRE DRIVE PRESSURE SETTING Most wires operate well with a pressure se�ng of “2”. The best drive roll pressure varies with wire type, wire surface, lubrica�on and hardness. Too much pressure may crush the wire or cause "birdnes�ng", but too li�le pressure could cause slippage.

  • Page 24: Lincoln, Standard #2-#4, Standard #5, Miller Gun Adapter Installation

    PIPEFAB™ WELDING SYSTEM INSTALLATION LINCOLN, STANDARD #2-#4, STANDARD #5, MILLER GUN ADAPTER INSTALLATION 1. Turn power OFF at the welding power source. 2. Using a Phillips screwdriver, remove the screw, lock washer and washer securing the gun adapter cover. Remove the gun adapter cover. FIGURE A.9 3.
  • Page 25 PIPEFAB™ WELDING SYSTEM INSTALLATION 4. Use a 1/8” hex key, loosen the set screw securing the gun adapter. FIGURE A.11 5. Using a Phillips screwdriver, remove the sense lead. FIGURE A.12 6. If a gas hose is a�ached to the gun adapter, use pliers to remove the hose clamp and remove the gas hose.
  • Page 26 PIPEFAB™ WELDING SYSTEM INSTALLATION 7. If the gun adapter requires guide tubes, install the correct size guide tube and secure with the set screw. FIGURE A.13 Wire size Number of grooves in guide tube .023 – .045” (0.6 – 1.2 mm) .045 –...

  • Page 27: Oxo And Fast Mate Gun Adapter Installation

    PIPEFAB™ WELDING SYSTEM INSTALLATION 12. Assemble the gun adapter cover and secure with the screw, lock washer and washer. FIGURE A.15 OXO AND FAST MATE GUN ADAPTER INSTALLATION Using the Oxo or FastMate gun adapters requires a K3344-1 Standard #4 gun adapter to be installed in the wire drive.
  • Page 28 PIPEFAB™ WELDING SYSTEM INSTALLATION 5. Bolt the electrode lead to the gun adapter, making sure to route the lead straight down. FIGURE A.17 6. Assemble the gun adapter cover and secure with the screw. FIGURE A.18 A-13...
  • Page 29 PIPEFAB™ WELDING SYSTEM INSTALLATION 7. Assemble the gas hose to the Oxo or FastMate gun adapter. FIGURE A.19 8. Select the appropriate guide tube and secure with the set screw. FIGURE A.20 Wire size Number of grooves in guide tube .023 –...

  • Page 30: Rotating The Wire Drive

    PIPEFAB™ WELDING SYSTEM INSTALLATION ROTATING THE WIRE DRIVE 1. Turn power OFF at the welding power source. 2. Locate the socket head cap screw at the bo�om of the wire drive. Loosen, but do not remove the screw. FIGURE A.21 3.

  • Page 31: Shielding Gas Connection

    PIPEFAB™ WELDING SYSTEM INSTALLATION SHIELDING GAS CONNECTION CYLINDER may explode if BUILD-UP OF SHIELDING GAS may damaged. harm health or kill. • Keep cylinder upright and chained to • Shut off shielding gas supply when not in support. use. Keep cylinder away from areas where it •...

  • Page 32: Water-Cooled Gun Connections

    PIPEFAB™ WELDING SYSTEM INSTALLATION WATER-COOLED GUN CONNECTIONS The K590-6 water connec�on kit installs underneath the wire drive. 1. Turn power OFF at the welding power source. 2. Install the quick disconnect fi�ngs to the plas�c bracket, by holding the rear nut sta�onary and spinning the fi�ng.

  • Page 33: Loading Spools And Coils

    PIPEFAB™ WELDING SYSTEM INSTALLATION LOADING SPOOLS AND COILS Keep hands, hair, clothing and tools away from rota�ng equipment. • • Do not wear gloves when threading wire or changing wire spool. Only qualified personnel should install, use or service this •...

  • Page 34: Electrical Installation

    PIPEFAB™ WELDING SYSTEM INSTALLATION ELECTRICAL INSTALLATION INPUT AND GROUND CONNECTION Only a qualified electrician should connect the PipeFab™. Installa�on should be made in accordance with the appropriate Na�onal Electrical Code, all local codes and the informa�on in this manual. FALLING EQUIPMENT can cause injury. •...
  • Page 35 PIPEFAB™ WELDING SYSTEM INSTALLATION ALWAYS CONNECT THE POWER WAVE GROUNDING LUG (LOCATED AS SHOWN IN FIGURES A.26 AND A.27) TO A PROPER SAFETY (EARTH) GROUND. FIGURE A.25 - CASE SIDE REMOVAL PULL SLIDE CASE SIDE TOWARD TILT CASE SIDE THEN REMOVE 4 SCREWS BACK OF THE MACHINE PULL UP TO REMOVE...

  • Page 36: Input Fuse And Suppy Wire Considerations

    PIPEFAB™ WELDING SYSTEM INSTALLATION INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS Refer to Technical Specifica�on Sec�on for recommended fuse, wire sizes and type of the copper wires. Fuse the input circuit with the recommended super lag fuse or delay type breakers (also called "inverse �me"...

  • Page 37: Pipefab Power Source Connector Locations

    PIPEFAB™ WELDING SYSTEM INSTALLATION PIPEFAB™ POWER SOURCE CONNECTOR LOCATIONS CASE FRONT LOCATIONS FIGURE A.27 1. Power Switch 2. Status LED 3. Thermal LED 4. Status II LED 5. 12 Pin Connector 6. Sense Lead Connector 7. Work Weld Output Terminal 8.
  • Page 38 PIPEFAB™ WELDING SYSTEM INSTALLATION CASE BACK LOCATIONS FIGURE A.28 1. TIG Gas Input Solenoid 2. Ethernet 3. MIG Weld Output Stud 4. ArcLink Connector 5. 40 Volt Circuit Breaker 6. Input Power Cord A-23...

  • Page 39: Pipefab Feeder Connector Locations

    PIPEFAB™ WELDING SYSTEM INSTALLATION PIPEFAB™ FEEDER CONNECTOR LOCATIONS FIGURE A.29 1. 5 Pin Trigger Connector 2. Gun Adapter 3. Input Weld Cable 4. 5 Pin ArcLink Cable 5. 12 Pin Remote UI Connector 6. MIG Input Gas Solenoid CONNECTION DIAGRAM The PipeFab™...

  • Page 40: Remote User Interface Configuration

    PIPEFAB™ WELDING SYSTEM INSTALLATION REMOTE USER INTERFACE CONFIGURATION A remote user interface (UI) can be added by simply plugging the PipeFab™ Remote UI into the PipeFab™ Feeder, 12 pin located on the back of the feeder. The remote UI is designed for hard automa�on setups with a manipulator.

  • Page 41: Remote Trigger Switch

    PIPEFAB™ WELDING SYSTEM INSTALLATION REMOTE TRIGGER SWITCH A remote trigger switch is available for use in hard automa�on setups with or without a Remote UI. This is a toggle switch and lead assembly which connects to the appropriate gun trigger connec�on to start and stop the wire feeder.

  • Page 42: Recommended Work Cable Sizes For Arc Welding

    PIPEFAB™ WELDING SYSTEM INSTALLATION RECOMMENDED WORK CABLE SIZES FOR ARC WELDING GENERAL GUIDELINES • Select the appropriate size cables per the “Output Cable Guidelines” below. Excessive voltage drops caused by undersized welding cables and poor connec�ons o�en result in unsa�sfactory welding performance.

  • Page 43: Cable Inductance And Its Effects On Welding

    PIPEFAB™ WELDING SYSTEM INSTALLATION CABLE INDUCTANCE AND ITS EFFECTS ON WELDING Excessive cable inductance will cause the welding performance to degrade. There are several factors that contribute to the overall inductance of the cabling system including cable size, and loop area. The loop area is defined by the separa�on distance between the electrode and work cables, and the overall welding loop length.
  • Page 44 PIPEFAB™ WELDING SYSTEM INSTALLATION If the auto sense lead feature is disabled and remote voltage sensing is enabled but the sense leads are missing or improperly connected extremely high welding outputs may occur. GENERAL GUIDELINES FOR VOLTAGE SENSE LEADS Sense leads should be a�ached as close to the weld as prac�cal, and out of the weld current path when possible.
  • Page 45 PIPEFAB™ WELDING SYSTEM INSTALLATION WORK VOLTAGE SENSING While most applica�ons perform adequately by sensing the work voltage directly at the output stud, the use of a remote work voltage sense lead is recommended for op�mal performance. The remote WORK sense lead (21) can be accessed through the four pin voltage sense connector located on the control panel by using the K940 Sense Lead Kit.

  • Page 46: Voltage Sensing Considerations For Multiple Arc Systems

    PIPEFAB™ WELDING SYSTEM INSTALLATION VOLTAGE SENSING CONSIDERATIONS FOR MULTIPLE ARC SYSTEMS Special care must be taken when more than one arc is welding simultaneously on a single part. Mul�ple arc applica�ons do not necessarily dictate the use of remote work voltage sense leads, but they are strongly recommended.

  • Page 47: Control Cable Connections

    PIPEFAB™ WELDING SYSTEM INSTALLATION CONTROL CABLE CONNECTIONS ArcLink Control Cables are available in two forms: K1543-xx series for most indoor or factory installa�ons. K2683-xx series when the equipment is frequently moved. ArcLink/LincNet control cables are special high quality cables for digital communica�on. The cables are copper 5 conductor cable in a SO-type rubber jacket.
  • Page 48 PIPEFAB™ WELDING SYSTEM INSTALLATION CONNECTION BETWEEN POWER SOURCE AND ETHERNET NETWORKS The PipeFab™ is equipped with a ODVA compliant RJ-45 Ethernet connector, which is located on the front panel. It is cri�cal that all Ethernet cables external to either a conduit or an enclosure are solid conductor, shielded cat 5e cable, with a drain.
  • Page 49 PIPEFAB™ WELDING SYSTEM INSTALLATION To install: 1. Turn the input power off at the welding power source. 2. Connect one end of the center lead to the power source electrode connec�on, and the other end to the wire feeder electrode connec�on. 3.

  • Page 50: Feeder Connectors

    PIPEFAB™ WELDING SYSTEM INSTALLATION FEEDER CONNECTORS ADVANCED ACCESSORIES CONNECTOR (12 PIN) TABLE A.5 PICTURE FUNCTION WIRING CAN LOW CAN HIGH NOT USED NOT USED NOT USED 12 PIN NOT USED CONNECTOR FOR PIPEFAB™ NOT USED REMOTE UI. NOT USED 40 VDC COMMON 40 VDC + NOT USED NOT USED...
  • Page 51 PIPEFAB™ WELDING SYSTEM INSTALLATION ARCLINK CONNECTOR (5 PIN) TABLE A.7 PICTURE FUNCTION WIRING 5 PIN CONNECTOR 67 ELECTRODE VOLTAGE SENSE COMMUNICATION AND POWER. 40 VDC COMMON A-36...

  • Page 52: Operation

    PIPEFAB™ WELDING SYSTEM OPERATION OPERATION SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. ELECTRIC SHOCK CAN KILL. • Do not touch electrically live part or electrode with skin or wet clothing. • Insulate yourself from work and ground. •...
  • Page 53 PIPEFAB™ WELDING SYSTEM OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL TABLE B.1 WARNING OR WELDING THERMAL CAUTION AMPERAGE INPUT WELDING SHIELDING GAS POWER VOLTAGE WIRE FEED ARC START SPEED PARAMETERS ARC END TRIM PARAMETERS POSITIVE DANGEROUS WORK OUTPUT...
  • Page 54 PIPEFAB™ WELDING SYSTEM OPERATION OUTPUT 4-STEP OPERATORS CURRENT TRIGGER MANUAL CIRCUIT CV PROCESS TIG PROCESS BREAKER STICK PROCESS...
  • Page 55 PIPEFAB™ WELDING SYSTEM OPERATION DEFINITIONS BASIC DEFINITIONS Arc Force – Arc Force adjusts the short circuit current for a so� arc, or for a forceful, driving arc. It helps to prevent s�cking and shor�ng of organic coated electrodes, par�cularity globular transfer types such as stainless and low hydrogen.
  • Page 56 PIPEFAB™ WELDING SYSTEM OPERATION Start Time – Controls the WFS and voltage for a specified �me at the end of the weld a�er the trigger is released. During the Crater �me, the machine will ramp from the Weld Procedure to the Crater Procedure.

  • Page 57: Power-Up Sequence

    The serviceability of a product or structure u�lizing the welding programs 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 applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrica�on methods and...

  • Page 58: User Interactions

    PIPEFAB™ WELDING SYSTEM OPERATION USER INTERACTIONS WIRE DRIVE SELECTION Pressing the Feedhead Select rocker towards the le� side will ac�vate the le� wire drive while pressing the right side will ac�vate the right wire drive. The ac�ve wire drive may also be selected by pulling the gun trigger on the le�...
  • Page 59 PIPEFAB™ WELDING SYSTEM OPERATION COLD FEED Pressing the Cold Feed rocker switch feeds wire forward at the indicated speed for as long as the switch is held. When connected to the PipeFab™ Remote UI, Cold Feed may be ac�ve by the rocker switch on the side of the feeder or the rocker switch on the front of the Remote UI.

  • Page 60: User Interface Layout

    PIPEFAB™ WELDING SYSTEM OPERATION USER INTERFACE LAYOUT FIGURE B.6 1. Process Adjustment Knob: Turn to adjust setpoint (dependent on the process). 2. Process Adjustment Knob: Turn to adjust setpoint (dependent on the process). 3. Menu Knob: Turn to scroll through the menu and press to select a highlighted op�on. 4.

  • Page 61: User Interface Navigation

    PIPEFAB™ WELDING SYSTEM OPERATION USER INTERFACE NAVIGATION NOTE: simplified home screens are used by default. To see the Home Screens as shown in the examples, set the HOME SCREEN LAYOUT to ADVANCED. STICK HOME SCREEN FIGURE B.7 1. Menu Bar - Use the Menu knob to scroll through the op�ons along the bo�om of the screen. Press the knob to select the highlighted op�on.
  • Page 62 PIPEFAB™ WELDING SYSTEM OPERATION TIG HOME SCREEN FIGURE B.8 1. Menu Bar - Use the Menu knob to scroll through the op�ons along the bo�om of the screen. Press the knob to select the highlighted op�on. 2. Current Se�ng - Sets the desired current, use le� knob to adjust. 3.
  • Page 63 PIPEFAB™ WELDING SYSTEM OPERATION TIG START/END SETTINGS FIGURE B.9 1. Set all to Auto – Start/End se�ngs are set to “auto” by default. These se�ngs are programmed based on process and setpoint to provide ideal welding. 2. Start Time – Controls the voltage for a specified �me at the beginning of the weld. During that �me, the machine will ramp from the Start Procedure to the Welding Procedure.
  • Page 64 PIPEFAB™ WELDING SYSTEM OPERATION FCAW HOME SCREEN FIGURE B.10 1. Feedhead Indicator – Shows which side of the wire feeder is selected and ready for setup. The ac�ve side can be selected by pressing the Feedhead Select Switch, Cold Feed Switch, or the gun trigger for the desired side.
  • Page 65 PIPEFAB™ WELDING SYSTEM OPERATION MIG HOME SCREEN FIGURE B.11 1. Feedhead Indicator – Shows which side of the wire feeder is selected and ready for setup. The ac�ve side can be selected by pressing the Feedhead Select Switch, Cold Feed Switch, or the gun trigger for the desired side.
  • Page 66 PIPEFAB™ WELDING SYSTEM OPERATION FCAW/MIG START/END SETTINGS FIGURE B.12 1. Set all to Auto – Start/End se�ngs are set to “auto” by default. These se�ngs are programmed based on process and setpoint to provide ideal welding. The se�ngs may be adjusted if desired. 2.
  • Page 67 PIPEFAB™ WELDING SYSTEM OPERATION SYSTEM MENU FIGURE B.13 1. USB Memory Media Connected. 2. Memories – View the saved memories for each process. 3. Language – Language of the text present in the user interface. 4. Display Units – Selects the units to display wire feed speed, metric or imperial. 5.
  • Page 68 PIPEFAB™ WELDING SYSTEM OPERATION ADVANCED SYSTEM SETTINGS FIGURE B.14 1. So�ware Versions – Allows access to a list of so�ware components grouped by system component. Also lists the IP address of the Ethernet port. See Figure B.15 on page B-18. B-17...
  • Page 69 PIPEFAB™ WELDING SYSTEM OPERATION FIGURE B.15 2. Weld Feedback Persist – When Weld Feedback Persist controls how long the actual welding voltage and current are displayed a�er comple�on of a weld. When Weld Feedback Persist is ON the actual welding voltage and current will remain on the display un�l the center knob on the display is turned or un�l the next weld starts.
  • Page 70 PIPEFAB™ WELDING SYSTEM OPERATION FIGURE B.16 Operator Restric�ons System Menu – OFF/ON, restricts changes to the System Menu. Wave Controls – OFF/ON, restricts changes to Wave Controls (i.e. Pinch, Arc Force, Ul�marc). Start/End Se�ngs – OFF/ON, restricts changes to Start/End Se�ngs. Remote Range –...
  • Page 71 PIPEFAB™ WELDING SYSTEM OPERATION SIMPLIFIED HOME SCREEN FIGURE B.17 1. Feedhead Indicator – Shows which side of the wire feeder is selected and ready for setup. The ac�ve side can be selected by pressing the Feedhead Select Switch, Cold Feed Switch, or the gun trigger for the desired side.
  • Page 72 PIPEFAB™ WELDING SYSTEM OPERATION MORE SETTINGS MENU (ALL PROCESSES) FIGURE B.18 1. Advanced se�ngs will appear here. Each weld process will have different se�ngs. The most common advanced se�ngs are: Pinch, Arc Force, Hot Start, Pre-Flow Time, Post-Flow Time, 2- Step/4-Step Trigger, and Ul�marc.
  • Page 73 PIPEFAB™ WELDING SYSTEM OPERATION PREVIOUS SETTING INDICATOR FIGURE B.19 1. Current Se�ng. 2. Previous Se�ng Indicator – The do�ed line will indicate where on the bar the most recent se�ng was. 3. Current Se�ng Indicator – Increasing the value will move the bar to the right, decreasing the value will move the bar to the le�.
  • Page 74 PIPEFAB™ WELDING SYSTEM OPERATION WELDING SCREEN FIGURE B.20 1. Output Ac�ve. 2. Feedhead Indicator – MIG and FCAW modes only. 3. Actual Current. 4. Actual Voltage. 5. Current Weld Se�ngs. B-23...
  • Page 75 PIPEFAB™ WELDING SYSTEM OPERATION BACK/HOME BUTTONS FIGURE B.21 1. Back Bu�on - Selec�ng the back bu�on takes the system back one screen. 2. Home Bu�on – Selec�ng the home bu�on takes the system back to the home screen. B-24...
  • Page 76 PIPEFAB™ WELDING SYSTEM OPERATION MEMORY OPERATION FIGURE B.22 Memories can be saved for each welding process. These can be accessed by touching the applicable memory bu�on labeled one through four. To save a memory, hold the desired memory loca�on down un�l the screen indicates the memory is saved.

  • Page 77: Front Panel Controls Of Remote Ui

    PIPEFAB™ WELDING SYSTEM OPERATION FRONT PANEL CONTROLS OF REMOTE UI FIGURE B.23 1. Process Adjustment Knob: Turn to adjust setpoint (dependent on the process). 2. Process Adjustment Knob: Turn to adjust setpoint (dependent on the process). 3. Menu Knob: Turn to scroll through the menu and press to select a highlighted op�on. 4.

  • Page 78: User Interface Programming

    PIPEFAB™ WELDING SYSTEM OPERATION USER INTERFACE PROGRAMMING Connect the 5-pin control cable from the wire feeder to the 5-pin connector on the PipeFab™ power source. Turn on the power to the wire feeder and wait for the ini�aliza�on sequence to complete. Insert the USB s�ck into the USB port on the user interface.
  • Page 79 PIPEFAB™ WELDING SYSTEM OPERATION WAVE EFFECT / PROCESS CONTROL DESCRIPTION RANGE NAME ULTIMARC REGULATES THE FOCUS OR SHAPE OF THE ARC. ULTIMARC VALUES GREATER THAN 0.0 INCREASE THE PULSE FREQUENCY WHILE DECREASING THE BACKGROUND CURRENT, RESULTING IN A TIGHT, STIFF ARC BEST FOR HIGH SPEED SHEET METAL WELDING.

  • Page 80: Trigger Selection

    PIPEFAB™ WELDING SYSTEM OPERATION TRIGGER SELECTION 2-STEP TRIGGER 2-Step Trigger controls the welding sequence in direct response to the trigger. When the gun trigger is pulled, the welding system (power source and wire feeder) cycles through the arc star�ng sequence and into the main welding parameters.
  • Page 81 PIPEFAB™ WELDING SYSTEM OPERATION Example 2: 2-Step Trigger: Improved Arc Start and Arc End. Tailoring the arc start and arc end is a common method for reducing spa�er and improving weld quality. This can be accomplished with the Start and Burnback func�ons set to a desired values and Crater set to OFF.
  • Page 82 PIPEFAB™ WELDING SYSTEM OPERATION Example 3: 2-Step Trigger: Customized Arc Start, Crater and Arc End. Aluminum is an example of where start, crater and burnback are commonly used to improve welding performance. For this sequence, PREFLOW: Shielding gas begins to flow immediately when the gun trigger is pulled. RUN-IN: A�er preflow �me expires, the power source regulates to the start output and wire is advanced towards the work piece at the Run-In WFS.
  • Page 83 PIPEFAB™ WELDING SYSTEM OPERATION 2-STEP TRIGGER: SPECIAL CONSIDERATIONS The weld sequence response depends upon when the trigger is pulled and released and whether or not START or CRATER are ac�ve. An example sequence: Pull the trigger to start feed of wire. When arc is established the sequencer will begin START/UPSLOPE. If trigger is released during UPSLOPE and CRATER/DOWNSLOPE is ac�ve, the machine will begin CRATER/DOWNSLOPE and sloping down over the CRATER �me, regardless of when the trigger release occurred.
  • Page 84 PIPEFAB™ WELDING SYSTEM OPERATION 4-STEP TRIGGER 4-step trigger allows the operator to release the trigger once an arc has been established. To end the weld, the trigger is pulled and then released again. Two types of 4-Step Trigger are available. Use the set-up menu to select the desired type of opera�on. With current interlock, if the arc goes out for more than 0.5 seconds while the trigger is released, the welding process stops and goes to the idle state.
  • Page 85 PIPEFAB™ WELDING SYSTEM OPERATION Example 2: 4-Step Trigger: Manual Control of Start and Crater �mes with Burnback ON. The 4-Step trigger sequence gives the most flexibility when the Start, Crater and Burnback func�ons are ac�ve. This is a popular choice when welding aluminum because extra heat may be needed during Start and less heat desired during crater.
  • Page 86 PIPEFAB™ WELDING SYSTEM OPERATION 4-STEP TRIGGER: SPECIAL CONSIDERATIONS The response to the trigger with 4-step trigger ac�ve is dependent upon when the trigger is pulled/released and the se�ngs for START and CRATER. Example 1: Pull the trigger to start feed of wire. When arc is established the sequencer will remain in START un�l the trigger is released.

  • Page 87: Start Options

    PIPEFAB™ WELDING SYSTEM OPERATION START OPTIONS The Start Op�ons available depend upon the process and weld mode selected. TABLE B.3 START EFFECT / PROCESS DESCRIPTION OPTION RANGE STICK PREFLOW 0 – 60.0 TIME SECONDS RUN-IN SETS THE WIRE FEED SPEED FROM THE TIME AUTO, OFF, THE TRIGGER IS PULLED UNTIL AN ARC IS ESTABLISHED OR 2.5 SECONDS.

  • Page 88: End Options

    PIPEFAB™ WELDING SYSTEM OPERATION END OPTIONS The End Op�ons available depend upon the process and weld mode selected. TABLE B.4 START EFFECT / PROCESS DESCRIPTION OPTION RANGE STICK CRATER PROCEDURE CONTROLS THE WFS AND VOLTS FOR A SPECIFIED TIME AT THE END OF THE WELD AFTER THE TRIGGER IS RELEASED.

  • Page 89: Kits, Optionsand Accessories

    PIPEFAB™ WELDING SYSTEM KITS, OPTIONS AND ACCESSORIES KITS, OPTIONS AND ACCESSORIES All Kits Op�ons and Accessories are found on the Web site: (www.lincolnelectric.com) FIELD INSTALLED OPTIONS PipeFab™ Kits TABLE C.1 K NUMBER DESCRIPTION K3736-1 PIPEFAB™ UNDERCARRIAGE K3737-1 PIPEFAB™ COOLER K3738-1 PIPEFAB™...

  • Page 90: Drive Roll And Wire Guide Kits

    PIPEFAB™ WELDING SYSTEM KITS, OPTIONS AND ACCESSORIES DRIVE ROLL AND WIRE GUIDE KITS TABLE C.3 DRIVE ROLL KITS, STEEL WIRES KP1505-030S .023 - .030” (0.6 - 0.8 MM) KP1505-035S .035” (0.9 MM) INCLUDES: 4 SMOOTH V KP1505-045S .045” (1.2 MM) GROOVE DRIVE ROLLS AND KP1505-052S .052”...

  • Page 91: Gun Adapter Kits

    PIPEFAB™ WELDING SYSTEM KITS, OPTIONS AND ACCESSORIES GUN ADAPTER KITS TABLE C.4 K NUMBER DESCRIPTION K3344-1 GUN ADAPTER KIT, LINCOLN BACK-END. INCLUDES A GUIDE TUBE KIT. KP4069-1 GUIDE TUBE KIT FOR K3344-1 LINCOLN GUN ADAPTERS. K3345-1 GUN ADAPTER KIT, STANDARD #2-#4 BACK-END. K3346-1 GUN ADAPTER KIT, STANDARD #5 BACK-END.

  • Page 92: General Accessories

    PIPEFAB™ WELDING SYSTEM KITS, OPTIONS AND ACCESSORIES GENERAL ACCESSORIES TABLE C.6 K NUMBER DESCRIPTION NOTES INCOMING BUSHING K1546-1 USE WITH .025 – 1/16” WIRES. FOR LINCOLN CONDUIT INCOMING BUSHING K1546-2 USE WITH 1/16” TO 1/8” WIRES. FOR LINCOLN CONDUIT K1733-1 WIRE STRAIGHTENER STRAIGHTEN WELDING WIRE TO IMPROVE FEEDING WATER CONNECTION...
  • Page 93 PIPEFAB™ WELDING SYSTEM MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE. ELECTRIC SHOCK can kill. • Do not operate with covers removed. • Turn off power source before installing or servicing. • Do not touch electrically hot parts. •...
  • Page 94 PIPEFAB™ WELDING SYSTEM MAINTENANCE Every year inspect the gearbox and coat the gear teeth with a moly-disulfide filled grease. DO NOT use graphite grease. CALIBRATION SPECIFICATION Output Voltage and Current are calibrated at the factory. Generally the machine calibra�on will not need adjustment.
  • Page 95 PIPEFAB™ WELDING SYSTEM DIAGRAMS J4 1...
  • Page 96 PIPEFAB™ WELDING SYSTEM DIAGRAMS REAR OF MACHI NE...
  • Page 98 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 99 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 100 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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