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Power Feed 11 SemiAutomatic
For use with: Power Feed 11 K1635-1 (World Model) Code 10529; 10777
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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
RETURN TO MAIN MENU
Cabinet Wire Feeder
Power Feed 11 K1636-1 (European Model) Code 10531; 10778
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2000 Lincoln Global Inc.
IM613-B
October, 2000
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric IM613-B
Summary of Contents for Lincoln Electric IM613-B
- Page 1 • 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 RETURN TO MAIN MENU Copyright © 2000 Lincoln Global Inc. IM613-B October, 2000...
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Page 2: California Proposition 65 Warnings
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: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
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Page 7: Table Of Contents
TABLE OF CONTENTS Installation ...Section A Technical Specifications ...A-1 Safety Precautions ...A-2 Wire Feeder to Power Source Configurations ...A-2 Mounting on Top of the Power Source...A-2 Hanging ...A-2 On the Floor ...A-2 Control Box Orientation ...A-2 Cable Connections ...A-3 Control Cable Connections ...A-3 Control Cable Specifications ...A-3 Typical Cabinet Feeder Connection ...A-3 Control Cable Installation ...A-3... - Page 8 Troubleshooting ...Section E Safety Precautions ...E-1 Troubleshooting Guide ...E-2 Diagrams ...Section F Wiring (Power Feed 11 Wire Feeder) ...F-1 Wiring (Power Feed 11 Control Box) ...F-2 Dimension Print...F-3 Parts Lists ...P315 Series TABLE OF CONTENTS Page...
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Page 9: Installation
TECHNICAL SPECIFICATIONS – Power Feed 11 SPEC.# TYPE LOW SPEED RATIO Speed K1635-1 Power Feed 11 50-625 IPM Cabinet (1.27-15.9 m/m) Wire Feeder (World Model) K1636-1 Power Feed 11 50-625 IPM Cabinet (1.27-15.9 m/m) Wire Feeder (European Model) SPEC.# TYPE INPUT POWER K1635-1 Power... -
Page 10: Safety Precautions
SAFETY PRECAUTION ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this installation. • Turn off the input power to the power source at the disconnect switch or fuse box before working on this equipment. Turn off the input power to any other equipment connected to the welding system at the disconnect switch or fuse box before work- ing on this equipment. -
Page 11: Cable Connections
CABLE CONNECTIONS CONTROL CABLE CONNECTIONS • All system control cables are the same. • All control cables can be connected end to end to extend their length. • All system equipment must be connected to a con- trol cable. Welding systems using the Power Feed 11 offer previ- ously unprecedented flexibility in the connection of system components. -
Page 12: Work Cable Connections
WORK CABLE CONNECTIONS Connect a work lead of sufficient size and length (per the following table) between the proper output termi- nal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work or wire feeder. - Page 13 RATIO CHANGE PROCEDURE: 1) Power down the Power Feed by turning OFF its companion PowerWave power source. For maxi- mum safety, disconnect the control cable from the Power Feed. 2) Pull open the Wire Feeder’s Compartment Door. 3) Remove the Feedplate per the following: a) Disconnected the Electrode from the Feedplate b) Pull open the Wire Drive Pressure Door.
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Page 14: Dip Switch Setup
DIP SWITCH SETUP SETTING SWITCHES CONTROL BOX There are two DIP switch banks on the mother board of the Control Box. They are labeled S1 and S2 and are located and oriented as shown in Figure A.3. S1 DIP Switch Bank on Control Box Motherboard (For Software version S24456-1) Switch Standard speed limits adjustable WFS Display = inches/minute... -
Page 15: Setting Dip Switches In The Wire Drive
S2 DIP Switch Bank on Control Box Motherboard (For software version S24456-1) Switch Network Group ID, MSB (Assigns Control Box to a specific group) (Off is factory setting) Network Group ID, LSB (Assigns Control Box to a specific group ) (Off is factory setting) 4-Step Domestic Configuration Power Feed 10 / Dual Procedure change with trigger “OFF”... -
Page 16: Wire Feed Drive Roll Kits
WIRE FEED DRIVE ROLL KITS AND FAST-MATE™ GUIDE TUBES NOTE: The maximum rated solid and cored wire sizes and selected drive ratios are shown on the SPECIFICATIONS in the front of this section. The electrode sizes that can be fed with each drive roll and wire guide are stenciled on each part. -
Page 17: Gun And Cable Assemblies
7) Insert inner Wire Guide, groove side out, over the two locating pins in the feed plate. 8) Install each drive roll by pushing over shaft until it butts up against locating shoulder on the drive roll shaft. (Do Not exceed maximum wire size rating of the wire drive). -
Page 18: Gmaw Shielding Gas
• Keep cylinder upright and chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other live elec- trical circuits. -
Page 19: Optional Features Installation
A-11 OPTIONAL FEATURES INSTALLATION A number of Optional Features are available for use with Power Feed 11. Some Installation informa- tion is provided in this section, REFER TO THE INSTRUCTIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLA- TION. -
Page 20: Operation
SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • When inching with gun trigger, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released. - Page 21 The user adjusts WFS according to factors such as weld size, penetration requirements, heat input, etc. The power source then uses the WFS setting to adjust its output char- acteristics (output voltage, output current) according to pre- programmed settings contained in the power source. In constant current modes (arc gouging, stick, TIG) this control adjusts the output current, in amps.
- Page 22 K1542-12 MSP2 Panel: (Optional) This panel provides a selection of over 25 weld modes, including CV, pulse, FCAW and CC, through a toggle switch and indicator lights (LEDs). It allows for adjustment of all set up parameters, Preflow, Run In, Arc Control, Burnback, Postflow, and Crater, through an up/down toggle switch, indicator lights and a 3 digit display.
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Page 23: Control Box Panels - Set Up Controls Description
To recall a memory setting, simply push that memory button. That memory’s contents will be immediately recalled to the Control box. If the ‘Memory Change with Trigger Pull’ DIP switch is on (see “Setting DIP Switches in the Control Box” sec- tion) it is possible to recall a given memory by quickly pulling and releasing the gun trigger before welding. -
Page 24: Control Box - Setting Operating Limits
CONTROL BOX -- SETTING OPERATING LIMITS Upper and lower operating limits can be set for the WFS/Amps setting and the Volts/Trim setting. Doing so requires knowledge of how to set the limits, and access to the PC board in the Control Box. There are two independent sets of limits, Procedure A limits and Procedure B limits. -
Page 25: Wire Drive Operation
WIRE DRIVE OPERATION The most frequently used Wire Drive settings are external; some features are accessed by internal set- tings. WIRE DRIVE SETTINGS -- EXTERNAL 2 STEP/4 STEP SWITCH: The Wire Drive has a 2 Step/ 4 Step switch located near the gun connector. -
Page 26: Wire Drive -- Pc Board Adjustments
WIRE DRIVE -- PC BOARD ADJUSTMENTS ELECTRODE POLARITY: The system needs to be aware of the electrode polari- ty. A DIP switch setting on the Wire Drive PC board is used for this purpose. See INSTALLATION Section “Setting DIP Switches in the Wire Drive”. GEAR BOX RATIO: The systems needs to know which gear has been installed on the Wire Drive, low or high speed. -
Page 27: Feeding Electrode And Brake Adjustment
OPERATION 1) Press end of gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds. 2) If the wire "birdnests", jams, or breaks at the drive roll, the drive roll pressure is too great. -
Page 28: Making A Weld
MAKING A WELD 1. Use only a network compatible power source. 2. Properly connect the electrode and work leads for the correct electrode polarity. 3. Set all desired parameters such as trigger logic, Run-in Speed, Acceleration, Electrode polarity, etc. per “DIP SWITCH SETUP” in the INSTALLATION section. -
Page 29: Component Status Lights
B-10 COMPONENT STATUS LIGHTS Each network component has a single status light. The light is a bicolor, Green/Red, LED. The purpose of the status light is to allow the operator to quickly identify that the system is working properly or, if not, NOTE: The green light ON and steady indicates a normal functioning system. - Page 30 B-11 STATUS LIGHT STATES (CON’T) LED State Power Source LED Red LED blinking Power source needs to be reprogrammed. at a fast rate Contact your Local Authorized Lincoln Field Service Facility. Red LED ON and Power source has a non-recoverable hard- steady ware fault.
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Page 31: Accessories
TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS 0.023” - 0.025” 0.030” 0.035” 0.040” 0.045” 0.052” 1/16” 5/64” 3/32” Cored Electrode 0.030 0.035” 0.040” 0.045” 0.052” 1/16” 0.068” 5/64” 3/32” 7/64” 7/64” .120” Aluminum Electrode 0.035” 0.040” 3/64” 1/16” 3/32”... - Page 32 DESCRIPTION OF OPTIONAL CON- TROL BOX PANELS A number of Optional Features are available for use with Power Feed 11. Some Installation information is provided in this section, REFER TO THE INSTRUC- TIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLATION.
- Page 33 WIRE SPINDLE ADAPTERS K435 - Permits 14 lb. (6 kg) Innershield coils to be mounted on 2" (51 mm) O.D. spindles. K363P - Adapts Lincoln Readi-Reel coils of electrode 30 lb. (14 kg) and 22 lb. (10 kg) to a 2" (51 mm) spin- dle.
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Page 34: Maintenance
MAINTENANCE Safety Precautions WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • When inching with gun trigger, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released. -
Page 35: Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE 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 36: Troubleshooting
Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 1. Rough wire feeding or wire not feeding but drive rolls are turning. 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. - Page 37 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 2. Variable or “hunting arc. 3. Poor arc striking with sticking or “blast-offs”, weld porosity, narrow and ropy looking bead, or electrode stubbing into plate while welding. 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.
- Page 38 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 4. Tip seizes in diffuser. 5. Unit shuts off while welding or attempting to weld, status light is red/green alternating between colors every second. Unit tries to recover after 30 seconds and may repeat again.
- Page 39 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 7. No wire feed, solenoid, or arc voltage. Status LEDs are solid green. 8. No control of wire feed. All status lights are solid green. Preset WFS is adjustable on Control 9.
- Page 40 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 10. Speed does not change when weld current flows. Status lights are solid green. 11. Voltmeter and/or ammeter do not function properly even though status lights are solid green. Welding may vary from normal procedure.
- Page 41 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 14. Displays and/or indicator lights do not change when their corre- sponding switches and or knobs are activated to request a change. 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.
- Page 42 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 15. Display(s) are blank. 16. Dual Procedure is not function- ing when using remote dual pro- cedure switch. Status lights are solid green on CB and head boards. 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.
- Page 43 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 17. Dual Procedure is not function- ing when using the local dual procedure switch (on CB). Status lights are solid green on CB and Head boards. 18. Wire feed speed is consistent and adjustable, but operates at the wrong speed.
- Page 44 E-10 Observe all Safety Guidelines detailed throughout this manual Note: For any Err # listed below write down the error number for reference and try cycling power to see if the error clears itself. If not, refer to the What to Do column for the given Err. PROBLEMS (SYMPTOMS) Display shows any of the following:...
- Page 45 E-11 Observe all Safety Guidelines detailed throughout this manual Note: For any Err # listed below write down the error number for reference and try cycling power to see if the error clears itself. If not, refer to the What to Do column for the given Err. PROBLEMS (SYMPTOMS) Display shows any of the following:...
- Page 46 E-12 Observe all Safety Guidelines detailed throughout this manual Note: For any Err # listed below write down the error number for reference and try cycling power to see if the error clears itself. If not, refer to the What to Do column for the given Err. PROBLEMS (SYMPTOMS) Display shows any of the following:...
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Page 47: Power Feed
1 2 3 4 5 6 DIAGRAMS 2 3 4 4 5 6 512B 541D 542D 500D 540D 540A 541A 542A 540B 500A 540C POWER FEED 11 512B... - Page 48 DIAGRAMS 512C 500C POWER FEED 11...
- Page 49 DIAGRAMS POWER FEED 11...
- Page 50 NOTES POWER FEED 11...
- Page 51 Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...
- Page 52 ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...
- Page 53 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
- Page 54 • 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...