Lincoln Electric POWER FEED 10 A Operator's Manual
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Lincoln Electric POWER FEED 10 A Operator's Manual

Lincoln Electric POWER FEED 10 A Operator's Manual

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All manuals and user guides at all-guides.com
IM849
™
June, 2009
POWER FEED
10A CONTROLLER
11139
For use with machines having Code Numbers:
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 thought-
ful operation 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.
IP 21S
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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  • Page 1 All manuals and user guides at all-guides.com IM849 ™ June, 2009 POWER FEED 10A CONTROLLER 11139 For use with machines having Code Numbers: 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 ...
  • Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 All manuals and user guides at all-guides.com 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 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • Page 7: Table Of Contents

    All manuals and user guides at all-guides.com TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation........................Section A Technical Specifications....................A-1 Safety Precautions ......................A-2 Welding Voltage, Mechanical Hazards .................A-2 Location and Mounting....................A-2 High Frequency Protection....................A-2 Auxiliary Equipment Input Power Connection ...............A-2 Interfacing to the POWER FEED™ 10A CONTROLLER ........A-3 thru A-4 Controling Non-Lincoln Auxilliary Equipment ..........A-5 thru A-6 Connection Diagram System ..................A-7 Remote Sense Lead Specification ................A-8...
  • Page 8 All manuals and user guides at all-guides.com GENERAL INFORMATION TECHNICAL SPECIFICATIONS: POWER FEED™ 10A CONTROLLER SPEC.# TYPE 142:1 SPEED RATIO 95:1 SPEED RATIO Wire Size Wire Size POWER FEED™ 10A CONTROLLER Speed Solid Cored Speed Solid Cored with Power Feed 10SF K2362-1 10-200 IPM 7/32 in.

  • Page 9: Installation

    All manuals and user guides at all-guides.com INSTALLATION HIGH FREQUENCY PROTECTION SAFETY PRECAUTION WARNING Locate the POWER FEED™ 10A CONTROLLER away from radio controlled machinery. The normal operation of the POWER FEED™ 10A CONTROLLER may adversely affect ELECTRIC SHOCK can kill. the operation of RF controlled equipment, which may result •...

  • Page 10: Interfacing To The Power Feed™ 10A Controller

    All manuals and user guides at all-guides.com INSTALLATION Auxiliary Input Power Connection Instructions: Terminal blocks 48 and 49 are shipped connected to CR2 and CR3 (532 and 531 leads) and these relays 1. Remove two Phillips Head screws on right side of are connected to the 3-pin and 4-pin connectors locat- front panel of hinged door to access terminal strip.
  • Page 11 All manuals and user guides at all-guides.com INSTALLATION 7. Remove one of the plug buttons located on the bot- 4. Replace the Switch Panel on the POWER FEED™ tom of the POWER FEED™ 10A CONTROLLER 10A CONTROLLER with the blank panel included control box and install some type of strain relief for with the pendant box.
  • Page 12 All manuals and user guides at all-guides.com INSTALLATION FIGURE A.2 SWITCH GROUP SWITCH GROUP #2 SUPPLY #1 SUPPLY START TRAVEL AUTO STOP TRAVEL ON INCH UP FLUX FILL INCH DOWN NOTE: TRAVEL AUTO and TRAVEL ON should not be closed at the same time. Either one OR the other should be closed at any time, and must remain closed to keep particular Travel Mode active.
  • Page 13 All manuals and user guides at all-guides.com INSTALLATION 8. Connect input supply voltage per the Auxiliary Input Power Connection Instructions listed earlier. Shutdown #2 can be configured for Output Lockout mode by enabling option P.21 in the Setup Menu 9. The relays could also be used to provide contact (Refer to Section B, General Setup Mode Options).

  • Page 14: Connection Diagram System

    All manuals and user guides at all-guides.com INSTALLATION CONNECTION DIAGRAM SYSTEM POWER WAVE AC/DC 1000 K2344-1 POWER FEED 10A CONTROLLER CONTROL BOX K2362-1 CONTROL CONTROL 2 3 4 5 6 K1543-XX ARCLINK CONTROL CABLE K1785-xx 14 — 14 PIN FEEDER CABLE ELECTRODE SENSE LEAD POWER FEED 10SF...

  • Page 15: Remote Sense Lead Specification

    All manuals and user guides at all-guides.com INSTALLATION REMOTE SENSE LEAD SPECIFICATIONS Welding with Multiple Arcs Special care must be taken when more than one arc is welding simultaneously on a single part. Arc blow and arc interference may occur or be magnified. Each power source requires a work lead from the work stud to the welding fixture.

  • Page 16: Operation

    All manuals and user guides at all-guides.com OPERATION SAFETY PRECAUTIONS DESIGN FEATURES Read this entire section of operating instructions • Mode Select Panel for easy control of all weld para- before operating the machine. meters. • Memory Panel for easy storage and recall of weld WARNING schedules.

  • Page 17: Product Description

    All manuals and user guides at all-guides.com OPERATION PRODUCT DESCRIPTION • When the POWER FEED™ 10A CONTROLLER is coupled to a Power Wave welding power source, the result is a welding system with the best arc perfor- General Physical Description mance on the market.

  • Page 18: Locating Front Panel Controls And Input, Output Connections

    All manuals and user guides at all-guides.com OPERATION LOCATING FRONT PANEL CONTROLS AND INPUT, OUPUT CONNECTIONS 14-PIN RECEPTACLE CONTROL BOX WITH DOOR 4-PIN TRAVEL RECEPTACLE 3-PIN FLUX RECEPTACLE 5-PIN INPUT RECEPTACLE CONTROL BOX WITHOUT DOOR POWER FEED™ 10A CONTROLLER...
  • Page 19 All manuals and user guides at all-guides.com OPERATION CASE FRONT CONTROLS CASE FRONT CONTROL DESCRIPTIONS 3. Status LED - The status LED indicates system sta- 1. DUAL DIGITAL DISPLAYS – Bright 7-segment dis- tus. Normal operation is a steady green light. plays showing welding parameter settings and actu- Note: During normal power-up, the LED may flash al levels while welding.

  • Page 20: Power-Up Sequence

    All manuals and user guides at all-guides.com OPERATION 11. INCH DOWN – Feeds the wire downward, toward the Blinking green Occurs during a reset and indi- work. NOTE: The Power Feed 10A includes an option in cates the power source is identify- the Setup Menu (P.15) to enable the touch sense circuit- ing each component in the system.

  • Page 21: Changing Weld Modes

    All manuals and user guides at all-guides.com OPERATION WELD MODE DESCRIPTION CHANGING WELD MODES 1. Allows wireless machine configuration using a Palm To select a weld mode, press the left Mode Select OS based hand-held computer. Panel pushbutton(7) until the WELD MODE LED(6) is illuminated (it may be illuminated by default at power 2.

  • Page 22: Ac Control

    All manuals and user guides at all-guides.com OPERATION AC CONTROL START OPTIONS Pressing the Left Mode Select Panel Pushbutton while in WELD MODE will illuminate the AC CONTROL Pressing the Right Mode Select Panel Pushbutton will LED (if AC parameters are available). Repeated illuminate the START OPTIONS LED.

  • Page 23: End Options

    All manuals and user guides at all-guides.com OPERATION END OPTIONS P.11 Pressing the Right Mode Select Panel Pushbutton after scrolling through the Start Options will illuminate Timers SETUP the END OPTIONS LED. Repeated pressing of the Right Mode Select Panel Pushbutton will toggle through the parameters.

  • Page 24: Weld Sequence Parameter List

    All manuals and user guides at all-guides.com OPERATION WELD SEQUENCE PARAMETER LIST PARAMETER UNITS RANGE DEFAULT VALUE WHERE IS IT SET? Arc Delay Time seconds 0-5.0 MSP4 - START OPTIONS Strike Fault Time seconds 0-10.0 MSP4- SETUP Menu Strike WFS from weld table* weld mode dependant Left Dual Display...

  • Page 25: General Setup Mode Options

    All manuals and user guides at all-guides.com B-10 B-10 OPERATION GENERAL SETUP MODE OPTIONS Pressing the right Mode Select Panel Pushbutton will enter into the Travel Options. Turning the Mode Select Panel Knob will toggle between TRAVEL STARTS The Setup Mode can be used to set more general and TRAVEL STOPS.

  • Page 26: Infrared (Ir) Control

    All manuals and user guides at all-guides.com B-11 B-11 OPERATION Here is a list of Lockout levels: Standard P.21 Shutdown PANEL LOCKOUT LEVEL Shutdown2 Select All Mode Select options unlocked (default). • Press the right Mode Select Button. All Mode Select options locked. •...

  • Page 27: Memory Panel Description

    All manuals and user guides at all-guides.com B-12 B-12 OPERATION MEMORY PANEL DESCRIPTION This panel performs these functions: limit setting and After holding the memory button in for two seconds memory saving/restoring. There are six user memo- the LED will turn off, indicating that the memory will be ries.

  • Page 28: Limit Setting

    All manuals and user guides at all-guides.com B-13 B-13 OPERATION One of these four items will blink to indicate which item LIMIT SETTING will change when the Mode Select Panel Knob is rotated. Initially, the selected item will be the attribute. To select Each user memory can be optionally configured to limit the high limit, press either Mode Select Panel button and the user’s range of control over some user interface set-...

  • Page 29: Accessories

    All manuals and user guides at all-guides.com ACCESSORIES GENERAL OPTIONS / K325 TC-3 Travel Carrriage ACCESSORIES K299 Wire Reel Assembly for 50-60lbs Coils K2311-1 Power Feed 10SM-Converts NA style wire K162-1 Spindle Kit – 2in. hub drives into Power Feed-10S Wire Drives Vertical Lift Adjuster K2370-1 Power Feed 10S Wire Drive-Power Feed- 10S with hardware to connect to a TC-3 Travel...

  • Page 30: Maintenance

    All manuals and user guides at all-guides.com MAINTENANCE SAFETY PRECAUTIONS ROUTINE MAINTENANCE WARNING • Check weld cables, control cables and gas hoses for cuts. ELECTRIC SHOCK can kill. • Do not touch electrically live parts • Clean and tighten all weld terminals. such as output terminals or internal wiring.

  • 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 All manuals and user guides at all-guides.com TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION LINC-NET SYSTEM ERROR CODES Err 006 1. The wire feeder has not received a recognition command from the power source.
  • Page 33 All manuals and user guides at all-guides.com TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION ARCLINK SYSTEM ERROR CODES Err 33 Capacitor bank "B" under 1. The power source input power voltage.
  • Page 34 All manuals and user guides at all-guides.com TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION ARCLINK SYSTEM ERROR CODES 1. Verify the earth ground connec- Err 44 Main CPU problem. tion to the power source is wired correctly.
  • Page 35 1. The electrode is rusty or dirty. feeding but drive rolls turning. Use only clean electrode. Use quality electrode, like L-50 or L- 56 from Lincoln Electric. 2. The contact tip is partially melted If all recommended possible areas of or has spatter. Replace the con- misadjustment have been checked tact tip.
  • Page 36 All manuals and user guides at all-guides.com TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Wire feed speed consistently oper- 1. The wire feeder gear setting is ates at the wrong value. not properly set.
  • Page 37 All manuals and user guides at all-guides.com DIAGRAMS SHIELDED CABLE FLEX POWER FEED™ 10A CONTROLLER...
  • Page 38 All manuals and user guides at all-guides.com DIMENSION PRINT POWER FEED™ 10A CONTROLLER...
  • Page 39 All manuals and user guides at all-guides.com 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...
  • Page 40 All manuals and user guides at all-guides.com 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. WARNING 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 41 All manuals and user guides at all-guides.com • 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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