Lincoln Electric 50448 Service Manual
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Lincoln Electric 50448 Service Manual

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SVM 3104
Rev.00 02-2020
LF52D - LF56D
For use with machines having code number: 50448, 50449
LINCOLN ELECTRIC EUROPE
www.lincolnelectric.eu

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  • Page 1 SVM 3104 Rev.00 02-2020 LF52D - LF56D For use with machines having code number: 50448, 50449 LINCOLN ELECTRIC EUROPE www.lincolnelectric.eu...

  • Page 2: Table Of Contents

    INDEX OF CONTENTS INDEX OF CONTENTS ............................2 TECHNICAL SPECIFICATIONS ........................3 ELECTROMAGNETIC COMPATIBILITY (EMC) ....................4 SAFETY ................................5 INSTALLATION AND OPERATOR INSTRUCTIONS ..................7 MAJOR COMPONENTS LOCATION ......................42 THEORY OF OPERATION ..........................43 TROUBLESHOOTING AND REPAIR SECTION .................... 45 ERROR CODES ...............................

  • Page 3: Technical Specifications

    TECHNICAL SPECIFICATIONS NAME INDEX LF 52D K14186-1 LF 56D K14187-1 INPUT Input Voltage U Input Amperes I EMC Class 40Vdc 4Adc RATED OUTPUT Duty Cycle 40° C Output Current (based on a 10 min. period) 100% 420A 500A OUTPUT RANGE Welding Current Range Peak Open Circuit Voltage 5 ÷...

  • Page 4: Electromagnetic Compatibility (Emc)

    If any electromagnetic disturbances are detected the operator must put in place corrective actions to eliminate these disturbances, if necessary with assistance from Lincoln Electric. Before installing the machine, the operator must check the work area for any devices that may malfunction because of electromagnetic disturbances.

  • Page 5: Safety

    Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or equipment damage. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages caused by improper installation, improper care or abnormal operation.
  • Page 6 CYLINDER MAY EXPLODE IF DAMAGED: Use only certificate, compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or transport gas cylinders with the protection cap removed.

  • Page 7: Installation And Operator Instructions

    INTRODUCTION LF 52D and LF 56D are digital wire feeders which have Power source – wire feeder set allow the welding: been designed to work with Lincoln Electric power GMAW (MIG/MAG) sources: FCAW ® POWERTEC i350S, SMAW (MMA) ® POWERTEC i420S, ®...
  • Page 8 Controls and Operational Features WARNING Maximum coolant pressure is 5 bar. Front panel LF 52D 4. Output Socket for the Welding Circuit: For connecting a wire with an electrode holder. 5. U0 User Interface (LF 52D): See „User Interface” section. 6.
  • Page 9 15. USB port (LF 56D only): For connecting the USB User Interface memory and software updates. Wire feeder LF 52D is based on a standard interface (U0) with two separate LED displays, while the LF 56D is 16. Wire Spool Holder: For wire spool with maximum based on a 7’’...
  • Page 10 Table 1 LED Light Conditions Welding process change Meaning It is possible to quick recall of one of the six manual LED Light welding programs - Table 2. Only machines which using CAN Condition protocol for communication Table 2 Manual Weld Modes: Correct operation mode.
  • Page 11 Quick Access and Configuration Menu Parameter Selection Mode – the parameter name on the left display [19] blinking. for U0 User Interface Users have access to the two menu levels: Parameter Change Value Mode – the parameter value on Quick Access – basic menu related with welding the right display [19] blinking.
  • Page 12 Advanced menu Press the right button [22], to confirm. To enter the menu (Table 4): Press the left button [23], to return to main menu. Press the right [22] and left button [23] simultaneously, to access the menu. WARNING Use the left knob [20], to choose the parameter. To exit from the menu with saved changes, press the left Press the right button [22], to confirm.
  • Page 13 Wire Feed Speed (WFS) unit – enables change of the displayed WFS unit: CE (factory default) - m/min; US - in/min. Hot Start - percentage regulation of growth nominal current value during arc start. It cause temporary rise up of output current which makes ignition of the electrode easier.
  • Page 14 Guide’s Marking Interface Table 5 Symbols description Select Welding Process Select Welding Program Process SMAW (MMA) Process GMAW Recall from the User Process FCAW (MIG/MAG) Memory Save to the User User setup Advanced Setup Memory Configuration Arc Force Hot Start Pinch Preflow Time Postflow Time...
  • Page 15 Advanced User Interface (U7) 32. Left Knob: Sets the value in the top left corner of the display. Cancel selection. Return to the previous menu. 33. Right Knob: Sets the value in the top right corner of the display. Cancel selection. Confirmation of changes. 34.
  • Page 16 Status bar Select Welding Program To select the Welding Program: Press the button [34] or right knob [33] to get access of Welding Parameters Bar. Use the right knob [33] to highlight the icon “Select Welding Process”. Press the Right knob [33] to confirm the selection. Figure 10 A - A/B Procedure B - Information about active welding mode...
  • Page 17 If user does not know the Welding Program Number, it Support can be choose manually. In that case please follow below To access the Support Menu: guide: Press the button [34] or right knob [33] to get access of Welding Parameters Bar. Welding Process Use the right knob [33] to highlight the icon “Support”.
  • Page 18 Table 9. User Setup Menu Symbol Description Preflow Time Postflow Time Burnback Time Spot Welding Settings Figure 17 WARNING Run-in WFS To remove the icon - press the right knob [33] once • again. To exit from User Setup Menu – press the left button Start Procedure •...
  • Page 19 Start Procedure – controls the WFS and Volts (or Trim) for a specified time at the beginning of welding. During the start time, the machine will ramp up or down from the Start Procedure to the preset Welding Procedure. Adjust time range: from 0 seconds (OFF) to 10 seconds. Crater Procedure –...
  • Page 20 Save – the following data can be save on a USB Memory Stick: (Table 11.): Table 11 Save and restore selection Symbol Description Current Welding Settings Advanced Parameters Configuration (P menu) Figure 23 All welding programs stored in user Confirm selection – press and hold for 3 second right memory knob [33].
  • Page 21 Press the right knob [33] to confirm. Figure 26 Press the right knob [33] to get access of “Save” option – Figure 30 the save menu is shown on the display. To confirm and save the data on USB Memory Stick, highlight the “Check Mark”...
  • Page 22 Press the right knob [33] to get access to “Load” menu – the load menu is shown on the display. Select the file name with the data to be loaded into interface. Highlight the “Load” icon – use the right knob [33].
  • Page 23 Settings and Configuration Menu Limits can be set for below parameters: Welding Current To access the Settings and Configuration Menu: Wire Feed Speed Press the button [34] or right knob [33] to get access to Welding Voltage Welding Parameters Bar. Hot Start right knob...
  • Page 24 Brightness Level It allows to adjust the display brightness from 0 to 10. Figure 41 Press button [34] to exit with saved changes. Display Configuration Settings Figure 44 Two Display configuration are available: Access control This function allows following activities: Table 13 Display Configuration Settings Table 14 Access control Symbol...
  • Page 25 Figure 46 Figure 49 Turn right knob [33] to select: numbers 0-9. WARNING Press right knob [33] to confirm first character of the To unlock function user have to perform the same steps password. as steps to lock function. Next characters should be selected in the same way. Enable/ Disable Jobs Save - it allows to WARNING switch off/on save jobs to memory...
  • Page 26 Figure 52 Figure 55 Press button [34] to return to main menu. WARNING The jobs which are disabled can not be using in “Save Enable/ Disable Jobs Mode or memory” function – shown Figure 53 (job 2 is not Select Jobs for Jobs Mode – user available).
  • Page 27 Restore Factory Setting WARNING After Factory Settings restore, the settings stored in user memory will be deleted. To restore factory settings: Access to “Configuration” menu. Use right knob [33] to highlight the “Restore Factory Settings’ icon. Figure 57 Press right knob [33] to confirm the selection. WARNING After activated Job Mode the icon of this function will be displayed on the Welding Parameters Bar.
  • Page 28 Figure 62 Press right knob [33]. The “Advance Manu” is shown on the display. Use the Right Knob [33] to highlight the parameter number which will be changed, for example P.1 - allows change units, factory default: "Metric" = m/min. Figure 63 Press right knob [33].
  • Page 29 Table 15 The Configuration Parameters The Menu Exit Enables exit from menu Wire Feed Speed (WFS) units Enables change WFS units: "Metric" (factory default) = m/min; "English" = in/min. Recall Memory with Trigger This option allows a memory to be recalled by quickly pulling and releasing the gun trigger: "Enable"...
  • Page 30 P.17 Remote Control Type This option selects the type of analog remote control being used. Digital remote control devices (those with a digital display) are configured automatically. "Push-Pull Gun" = Use this setting while MIG welding with a push-pull gun that uses a potentiometer for wire feed speed control (this setting is backward compatible with "P.17 Gun Selection"...
  • Page 31 P.28 Display Workpoint as Amps Determines how workpoint is displayed: Option "No" (factory default) = The workpoint is displayed in the format defined in the weld set. "Yes" = All workpoint values are displayed as an amperage. Note: This option may not be available on all machines. The power source must support this functionality, or this option will not appear in the menu P.80 Sense From Studs...
  • Page 32 Cooler Menu WARNING Cooler Menu is available when cooler is connected. Figure 66 Table 18 Service Menu Symbol Description Service weld logs Figure 65 Weld History Table 16 Cooler Menu Symbol Description SnapShot Settings Service weld logs - allows recording of the welding which were used during welding.
  • Page 33 This file can be sent to Lincoln Electric Support to troubleshoot any possible issues that cannot be easily resolved by the user. To obtain a SnapShot: Make sure that USB device is connected.
  • Page 34 Welding GMAW and FCAW Process in By applying the principle of occupational health and safety at welding, welding can be begun. non-synergic mode For non-synergic mode you can set: During non-synergic mode wire feed speed and welding Wire Feed Speed, WFS voltage are independent parameters that must be set by Welding Voltage the user.
  • Page 35 Welding SMAW Process Loading the Wire Spool Wire feeder LF 52D, LF 56D does not include the Wire spool type S300 and BS300 can be installed on the electrode holder with lead necessary for SMAW welding, wire spool support without adapter. ®...
  • Page 36 Wire Spool Type B300 Loading Loading the Electrode Wire Turn the input power OFF. Open the spool wire case. WARNING Unscrew the locking nut of the sleeve [16]. Turn the input power OFF at the welding power source Load the spool wire on the sleeve such that the spool before installation or changing a wire spool.
  • Page 37 Adjusting of Pressure Roll Force Changing Driving Rolls The pressure arm controls the amount of force the drive rolls exert on the wire. Pressure force is adjusted by WARNING turning the adjustment nut clockwise to increase force, Turn the input power off before installation or changing counterclockwise to decrease force.
  • Page 38 Gas Connection Transport and Lifting WARNING WARNING CYLINDER may explode if damaged. Falling equipment can cause injury and Always fix the gas cylinder securely in an damage to unit. upright position, against a cylinder wall rack or purpose-made cylinder cart. Keep cylinder away from areas where it may During transportation and lifting with a crane, adhere to be damaged, heated or electrical circuits to...
  • Page 39 We respond to our customers be lost. based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or Any noticeable damage should be reported immediately guarantee such advice, and assumes no liability, with and repaired.
  • Page 40 Interface description 51. Error code 52. Error description. Figure 75 Table 21 shows list of basic errors that can appear. To get full list of error codes, please contact with authorize Lincoln Electric service. Table 21 Error codes Error code Symptoms...
  • Page 41 CONNECTION CONFIGURATION...

  • Page 42: Major Components Location

    MAJOR COMPONENTS LOCATION LF52D – LF56D 1. Motor Board (mounted on the leftside panel) 4. Wire Drive 2. Gas Solenoid 5. Reel Hub 3. Motor 6. User Interface Board...

  • Page 43: Theory Of Operation

    THEORY OF OPERATION Wiring LF 52D Wiring LF 56D...
  • Page 44 Interface and sends the signals to energize the active GENERAL DESCRIPTION components such as the solenoid and wire drive motor. The LF52D and LF56D are a four rolls, digitally The tach feedback signal is also processed by this controlled, wire feeders that operates on 40 VDC input board which regulates the motor supply voltage to power.

  • Page 45: Troubleshooting And Repair Section

    TROUBLESHOOTING AND REPAIR SECTION  How to use troubleshooting Guide  Troubleshooting Guide  Error Codes  Case Cover Removal Procedure  Feeder Control Board test  User Interface Board test  Gas Solenoid test  Wire Drive Motor test ...
  • Page 46 HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only 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 47 WARNING NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature. 5. Remove the replacement PC board and ELECTRIC SHOCK can kill substitute it with the original PC board to recreate the original problem. Have an electrician install and service this If the original problem does not reappear •...
  • Page 48 MOTOR BOARD CONNECTOR These tests 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...

  • Page 49: Error Codes

    ERROR CODES Interface description 51. Error code 52. Error description. Figure 76 Table below shows the list of basic errors that can appear. To get full list of error codes, please contact with local authorize Lincoln Electric service. Error code Symptoms Cause Recommended Course of Action...

  • Page 50: Case Cover Removal Procedure

    CASE COVER REMOVAL PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician or 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 51 LF52D & LF56D - CASE COVER REMOVAL (continued) Figure 1 Figure 1a Necessary tool: - Torx T25 wrench Procedure: 1. Turn the power source ON/OFF switch to OFF position. 2. Disconnect Input Power from the power source ! 3. Remove the 2 screws (A) from the back of the left side feeder panel. See Figure 1 4.

  • Page 52: Feeder Control Board Test

    FEEDER CONTROL BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 53 FEEDER CONTROL BOARD TEST (continued) For LF52D Y035-1 Feeder Control Board Figure 1 - Feeder control board Figure 1a – Y035-1 Test point locations TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove input power from the wire feed unit. 2.
  • Page 54 FEEDER CONTROL BOARD TEST (continued) For LF56D Y057-5 Feeder Control Board Figure 1 - Feeder control board Figure 1a – Feeder Control Board Test points V301 V112 V320 V519 Figure 2 – LEDs location...
  • Page 55 FEEDER CONTROL BOARD TEST (continued) For LF56D TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove input power from the wire feed unit. 2. Perform the wire feeder case removal procedure. 3. Located the Feeder Control Board. See Figure 1. Do not remove the plugs from the Motor Control Board. 4.

  • Page 56: User Interface Board Test

    USER INTERFACE BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 57 USER INTERFACE BOARD TEST (continued) For LF52D V109 X100 Figure 1 – LF52D User Interface component side TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove input power from the wire feed unit. 2. Follow the LF52D User Interface removal procedure available inside this manual to get access to the connector X100.
  • Page 58 USER INTERFACE BOARD TEST (continued) For LF56D V718 Figure 1 – LF 56D User Interface component TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove input power from the wire feed unit. 2. Follow the LF56D User Interface removal procedure available inside this manual to get access to the connector X100.

  • Page 59: Gas Solenoid Test

    GAS SOLENOID TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 60 GAS SOLENOID TEST (continued) Wire 210 & Solenoid Figure 1 – Gas solenoid location TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove input power from the wire feed unit. 2. Perform the wire feeder case removal procedure. 3.

  • Page 61: Wire Drive Motor Test

    WIRE DRIVE MOTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 62 WIRE DRIVE MOTOR TEST (continued) LF 52D Wire drive motor LF 56D Figure 1 – Wire drive motor location and connectors TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove input power from the wire feed unit. 2.

  • Page 63: Wire Drive Motor Tachometer Test

    WIRE DRIVE MOTOR TACHOMETER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 64 WIRE DRIVE MOTOR TACHOMETER TEST (continued) LF 52D Wire drive motor and tachometer LF 56D Figure 1 – Wire drive motor and tachometer location TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove input power from the wire feed unit. 9.

  • Page 65: Disassembly Operations

    DISASSEMBLY OPERATIONS MOTOR CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE LF56D LF52D Figure 2 – Motor Control Figure 1 boards location REMOVAL PROCEDURE Necessary tools: - Torx T25 wrench - Screwdriver type PH02 1. Turn the power source ON/OFF switch to OFF position. 2.
  • Page 66 DISASSEMBLY OPERATIONS (continued) WIRE DRIVE MOTOR AND WIRE DRIVE PLATE REMOVAL AND REPLACEMENT PROCEDURE Figure 1 Figure 1a REMOVAL PROCEDURE Necessary tools: Screwdriver type PH02 3 mm allen wrench 10 mm wrench 1. Remove main input power from the Wire Feeder. 2.
  • Page 67 DISASSEMBLY OPERATIONS (continued) USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE For LF52D Use 2 mm Allen wrench to loosen the screw from the two knobs Figure 1b Figure 1 Figure 1a REMOVAL PROCEDURE Necessary tools: 8mm nut driver 14mm wrench 2 mm allen wrench Torx T25 PH02 screwdriver...
  • Page 68 DISASSEMBLY OPERATIONS (continued) USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE For LF52D Figure 2 10. Using the torx T25 wrench remove the 4 screw (A) that are fixing the User Interface assembly on the Feeder front panel. See Figure 2. 11.
  • Page 69 DISASSEMBLY OPERATIONS (continued) USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE For LF56D Figure 1b Figure 1 Figure 1c Figure 1a REMOVAL PROCEDURE Necessary tools: 8mm nut driver 14mm wrench 2 mm allen wrench Torx T25 PH02 screwdriver 1. Remove main input power from the Wire Feeder. 2.
  • Page 70 DISASSEMBLY OPERATIONS (continued) USER INTERFACE BOARD REMOVAL AND REPLACEMENT PROCEDURE For LF56D Figure 2 Figure 3 Figure 4 10. Using the torx T25 wrench remove the 4 screw (A) that are fixing the User Interface assembly on the Feeder front panel.
  • Page 71 DISASSEMBLY OPERATIONS (continued) GAS VALVE REMOVAL AND REPLACEMENT PROCEDURE Figure 1 Figure 2 REMOVAL PROCEDURE Necessary tools: 14mm wrench Pincers Metal clip 10,5 GER (part number 0656-790-105R) Threadlocker liquid 1. Remove main input power from the Wire Feeder. 2. Perform the wire feeder case removal procedure. 3.

  • Page 72: Calibration Procedure

    CALIBRATION PROCEDURE This calibration has to be performed using the Feeder, either LF-52D or LF-56D, connected to the machine. Prepare the external reference ammeter (A) and voltmeter (V). Connect a load to output with A and V. Enter to Service Mode: on the feeder, push the right button (LF 52D) or right encoder (LF 56D) and switch machine on.

  • Page 73: Electrical Schematics

    ELECTRICAL SCHEMATICS Schematic Diagram : LF 52D...
  • Page 74 ELECTRICAL DIAGRAMS Schematic Diagram : LF 56D...

  • Page 75: Note

    NOTE...

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