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Lincoln Electric IM658-A Operator's Manual

Power feed 10 dualwire drives & control boxes boom mount or bench model.
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Power Feed 10 Dual Wire Drives & Control Boxes
Boom Mount or Bench Model
For use with: Power Feed 10 Dual Wire Drive - Bo o om Mount Code 10625, 10788
Power Feed 10 Dual Boom Package Code 10622 (Generic), 10623 (12' Zipline), 10624 (16' Zipline),
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. And, most
importantly, think before you act
and be careful.
• 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
10785(Generic), 10786(12' Zipline), 10787(16' Zipline)
Power Feed 10 Dual Bench Model Code 10621, 10784
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2007 Lincoln Global Inc.
IM658-A
August, 2007

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   Summary of Contents for Lincoln Electric IM658-A

  • 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 © 2007 Lincoln Global Inc. IM658-A August, 2007...

  • 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 and CUTTING 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 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 LʼArc 1. Protegez-vous contre la secousse électrique: a.

  • 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

    TABLE OF CONTENTS Installation ...Section A Technical Specifications ...A-1 Safety Precautions ...A-2 Mounting the Wire Drive Unit ...A-2 Boom Mounting of Wire Drive ...A-2 Electrode Routing...A-2 Mounting the Control Box and Receptacle Configuration ...A-2 Separating the Control Box from the Wire Drive (Bench Model Only) ...A-2 Mounting the Control Box (Boom or Separated Bench Models) ...A-3 Determining Receptacle Configuration ...A-3 Mounting on Power Source ...A-3...

  • Page 8

    Troubleshooting ...Section E Safety Precautions ...E-1 Troubleshooting Guide ...E-2 Diagrams ...Section F Wiring (Power Feed 10 Dual Head) ...F-1 Control Box Dimension Print...F-2 Bench Model Dimension Print...F-3 Dual Wire Drive Dimension Print ...F-4 Parts Lists ...P346 Series TABLE OF CONTENTS Page...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS – Power Feed 10 Dual Wire Drives & Control Boxes WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO Speed K1685-1 Power Feed 50-800 IPM 10 Dual (1.27-20.3 m/m) Wire Drive* K1683-1, Power Feed 50-800 IPM -2,-3, 10 Dual...

  • Page 10: Safety Precautions

    SAFETY PRECAUTIONS 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: Mounting The Control Box (boom Or Separated Bench Models

    5. Remove plug button taped to inside of Control Box and insert it into hole on front panel of the Wire Drive. MOUNTING THE CONTROL BOX (BOOM OR SEPARATED BENCH MODELS) The back plate of the Control Box has four keyhole slots for mounting.

  • Page 12: Control Cable Specifications

    Wire Drive. Multiple Wire Drive Connection: For proper multiple wire drive connections and DIP switch settings contact the Lincoln Electric Company, Customer Service Department. Non-Typical Boom Feeder Connection: One control cable is connected from the Power Wave 455 output receptacle to the the input receptacle on the back of the Wire Drive.

  • Page 13: Work Cable Connections

    Connect the one end of the electrode cable, to the power source output terminal of the desired polarity. Connect the other end of the electrode cable to the connection bar at the front of the wire drive feed plate using the provided bolt and lockwasher. The trode cable lug must be against the feed plate.

  • Page 14

    RATIO CHANGE PROCEDURE: 1) Pull open the Pressure Door. 2) Remove the Phillips head screw retaining the pin- ion gear to be changed and remove the gear. If the gear is not easily accessible or difficult to remove, remove the feed plate from the gearbox. To remove feed plate: a) Loosen the clamping collar screw using a 3/16”...

  • Page 15: 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) Switch Standard speed gearbox limits adjustable WFS Display = inches/minute...

  • Page 16

    S2 DIP Switch Bank on Control Box Motherboard (For software version S24456) 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 / Dual Procedure Change with Trigger “OFF”...

  • Page 17: Setting Dip Switches In The Wire Drive

    SETTING DIP SWITCHES IN THE WIRE DRIVE There is one DIP switch bank on each Control PC board for the wire drives. They are labeled S1 and are located and oriented as shown in Figure A.4. The PC board for the left feed head (facing forward) is located on the rear access panel.

  • Page 18: Wire Feed Drive Roll Kits

    A-10 WIRE FEED DRIVE ROLL KITS NOTE: The maximum rated solid and cored wire sizes and selected drive ratios are shown on the SPECIFICATIONS in the front of this sec- tion. The electrode sizes that can be fed with each roll and guide tube are stenciled on each part.

  • Page 19: General Gun Connection Guidelines

    A-11 Magnum 200 / 300 / 400 Guns The easiest and least expensive way to use Magnum 200/300/400 guns with the Power Feed 10 Dual wire feeder is to order them with the K466-10 connector kit, or to buy a completely assembled Magnum gun hav- ing the K466-10 connector (such as the K497-21 dedi- cated Magnum 400).

  • Page 20: 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 21: Optional Features Installation

    A-13 OPTIONAL FEATURES INSTALLATION A number of Optional Features are available for use with Power Feed 10 Dual. 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 22: 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 23

    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 characteristics (output voltage, output cur- rent) according to pre-programmed settings contained in the power source. In constant current modes (arc gouging, stick, TIG) this control adjusts the output cur- rent, in amps.

  • Page 24

    Memory has an advanced feature called ʻmemory reminderʼ. When the Save key is hit, the memory reminder function flashes the LED of the most recently used memory, so the operator can save procedures in the most recently used memory if desired. It is not necessary to save to the most recently used memory;...

  • Page 25

    The value of the active Set Up parameter, as defined by the Set Up LED, is displayed on the MX2 panel Set Up display. The value can be modified with the Set switch. The Set switch is an up/down center-off momentary toggle switch.

  • Page 26

    Crater - Used only when welding with the 4-Step trig- ger mode. Can be set to Off or On. When On, Adjustments can be made to WFS and Volts/Trim on the Control/Display panel. These settings are then used for ʻcrateringʼ when in the 4-Step trigger mode (see explanation of 2 Step and 4 Step operation below).

  • Page 27: 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 on the gun side of the Status LED.

  • Page 28: 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 29

    FIGURE B.1 To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300 mm Diameter) or 14Lb.(6 Kg) Innershield Coils: The Spindle should be located in the LOWER mounting hole. (For 8" (200 mm) spools, a K468 spindle adapter must first be slipped onto spindle.) (For 13-14 lb.

  • Page 30: 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 31: Making A Weld

    B-10 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”...

  • Page 32: Component Status Lights

    B-11 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 33

    B-12 STATUS LIGHT STATES (CONʼT) 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.

  • Page 34: Accessories

    TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS Solid Steel Electrode 0.023” - 0.025” 0.030” 0.035” 0.040” 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” Lincore Hard Facing 7/64” .120”...

  • Page 35

    DESCRIPTION AND INSTALLATION OF OPTIONAL CONTROL BOX PANELS A number of Optional Features are available for use with Power Feed 10 Dual. 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 36

    K1542-6 “M” PANEL The M Panel provides a fixed large bat toggle switch selection of three Power Source modes. The upper position selects the generic CV/MIG mode from the power source, the middle position selects the CV/FLUX CORED mode, and the lower position selects the CC/STICK/GOUGE mode.

  • Page 37

    K1542-11 MX2 PANEL (LARGE PANEL) The MX2 Panel provides a selection of four Power Source modes. In addition, it provides for the adjustment of the following parameters: preflow, run in, arc control, Burn back, postflow, and spot time. Descriptions Indicator Lights - Extra bright red LEDʼs for viewing at almost any angle.

  • Page 38

    K1542-12 MSP2 PANEL AND K1542- 10 MS/STT PANEL (LARGE PANEL) The MSP2 or MS/STT Panel provides a selection of numerous process specific and generic Power Source modes. In addition, it provides for the adjustment of the following parameters: preflow, run in, arc control, Burn back, postflow, and spot time.

  • Page 39

    tings of the procedure by 10 percent. Lincoln Power Wave power sources utilizes a control scheme known as adaptive control in all pulse modes. Because the Power Wave utilizes adaptive control, it can adjust the pulsing parameters based on changes in the arc due to changes in the electrical sitckout of the electrode.

  • Page 40

    which procedure the gun switch is requesting. Memory Selection RECALL - When a memory key is depressed its indi- cator comes on, and its contents are copied to the active procedure. As long as no changes are made to the contents of that procedure, the memory indicator will be on anytime that procedure is active.

  • Page 41

    K1548-1 LINC NET RECEPTACLE KIT (INPUT AND OUTPUT) LINC NET RECEPTACLE (OUTPUT) Optional Output Connector Installation into the Control Box Cabinet and/or into the Feeder Head Enclosure. Control Box Cabinet Procedure 1. Turn off power. 2. Remove the screws from the front of the lower and middle option panels of the User Interface cabinet.

  • Page 42

    LINC NET RECEPTACLE (INPUT) Power Feed Wire Feeder Optional Input Connector Installation into the Control Box Cabinet and Conversion to Fixture Wire Feeder 1. Turn off power. 2. Remove the screws from the front of the lower and middle option panels of the Control Box cabi- net.

  • Page 43: Guns And Gun Adapters

    C-10 GUNS AND GUN ADAPTERS The Power Feed 10 Dual wire feeder is equipped with a factory installed K1500-2 gun connection Kit. This kit is for guns having a Tweco™ #2-#4 connector. The Power Feed 10 Dual has been designed to make con- necting a variety of guns easy and inexpensive with the K1500 series of gun connection kits.

  • Page 44: Dual Procedure Switch Options

    C-11 CONDUIT ADAPTERS K1546-2 ADAPTER for use with Lincoln Magnum conduit and E-Beam conduit (wire sizes 1/16 - .120) For Magnum conduit: Install the K1546-2 gun adapter at the incoming end of the feed plate, secure with the set screw located at the back of the feed plate.

  • Page 45

    C-12 K590-6 WATER CONNECTION KIT (FOR DRIVE ONLY) Install per the instructions shipped with the kit. K1536-1 WATER FLOW SENSOR Install per the instructions shipped with the kit K659-1 GAS GUARD REGULATOR Adjustable flow regulator with removable adjuster key for CO2 and Argon blend gases. Mounts onto feeder inlet, and reduces gas waste and arc start “blow”...

  • Page 46: 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 47: 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 48: 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 49

    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 50

    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 51

    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 52

    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 53

    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 54

    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 55

    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 56

    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 57

    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 58

    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:...

  • Page 59

    DIAGRAMS POWER FEED 10 DUAL...

  • Page 60

    DIAGRAMS POWER FEED 10 DUAL...

  • Page 61

    DIAGRAMS POWER FEED 10 DUAL...

  • Page 62

    DIAGRAMS • POWER FEED 10 DUAL...

  • Page 63

    NOTES POWER FEED 10 DUAL...

  • Page 64

    ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...

  • Page 65

    ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...

  • Page 66

    • 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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