Lincoln Electric POWER FEED IM584-D Operator's Manual
  1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. POWER FEED IM584-D
  6. Operator's manual

Lincoln Electric POWER FEED IM584-D Operator's Manual

Wire drive & control box boom mount or bench model
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
RETURN TO MAIN MENU
IM584-D
Power Feed 10 Wire Drive & Control Box
August, 2007
Boom Mount or Bench Model
For use with: Power Feed 10 Control Box - Boom Mount Code 10436, 10615
Power Feed 10 Wire Drive - Boom Mount Code 10437,10616, 10782
Power Feed 10 Boom Package Code 10435, 10612 (Generic), 10493, 10613 (12' Zipline), 10494, 10614 (16' Zipline),
10779 (Generic), 10767, 10780 (12' Zipline), 10768, 10781 (16' Zipline)
Power Feed 10 Bench Model Code 10438, 10617, 10760,10783
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.
OPERATOR'S MANUAL
Copyright © 2007 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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the POWER FEED IM584-D and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Lincoln Electric POWER FEED IM584-D

Summary of Contents for Lincoln Electric POWER FEED IM584-D

  • Page 1 RETURN TO MAIN MENU IM584-D Power Feed 10 Wire Drive & Control Box August, 2007 Boom Mount or Bench Model For use with: Power Feed 10 Control Box - Boom Mount Code 10436, 10615 Power Feed 10 Wire Drive - Boom Mount Code 10437,10616, 10782 Power Feed 10 Boom Package Code 10435, 10612 (Generic), 10493, 10613 (12’...

  • 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 Procedure for Replacing PC Boards ...E-13 Diagrams ...Section F Wiring (Power Feed 10 Control Box) ...F-1 Wiring (Power Feed 10 Feed Head) ...F-2 Dimension Print...F-3 Parts Lists ...P306 Series TABLE OF CONTENTS Page...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS – Power Feed 10 Wire Drive & Control Box WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO Low Speed K1540-1 Power Feed 10 50-800 IPM K1540-2 Wire Drive (1.27-20.3 m/m) K1538-1, Power Feed 10 50-800 IPM -2,-3,-4, Boom Package# (1.27-20.3 m/m)

  • 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. 1-800-833-WELD. 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

    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. S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only) 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)
  • Page 16 S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up) 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) Spare Spare Spare...
  • Page 17 S1 DIP Switch Bank on Control Box Motherboard (For software version S24456) Switch Standard speed gearbox limits adjustable WFS Display = inches/minute Left Display is always preset WFS CC modes override this switch regardless of position. Left Display is always preset weld cur- rent when weld current is not flowing and actual weld current when weld current is flowing Run-in = Minimum Speed Available If any option containing a Run-in setting is connected to the motherboard, it automatically...
  • Page 18 A-10 Setting Wire Drive Acceleration Rate Using DIP Switch S1 on the Control Box Motherboard Acceleration 1 (slow) Acceleration 2 Acceleration 3 Acceleration 4 Acceleration 5 (fast ) (factory setting) SETTING DIP SWITCHES IN THE WIRE DRIVE There is one DIP switch bank on the control board of the wire drive.

  • Page 19: Wire Feed Drive Roll Kits

    A-11 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 20: General Gun Connection Guidelines

    A-12 Magnum 200 / 300 / 400 Guns The easiest and least expensive way to use Magnum 200/300/400 guns with the Power Feed 10 wire feeder is to order them with the K466-10 connector kit, or to buy a completely assembled Magnum gun having the K466-10 connector (such as the K497-21 dedicated Magnum 400).

  • Page 21: 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 22: Optional Features Installation

    A-14 OPTIONAL FEATURES INSTALLATION A number of Optional Features are available for use with Power Feed 10. Some Installation information is provided in this section, REFER TO THE INSTRUC- TIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLA- TION.

  • Page 23: 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 24 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 25 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 26: Controls Description

    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 27 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 28: Operation With Previous Software Versions

    OPERATION WITH SOFTWARE VERSION The operation of the previous Control Box software version (S24004-2) is different than described earlier in this section. The differences are as follows: • The Memory/Dual Procedure panel is not a valid option. • The MX (K1542-1) and MSP (K1542-8) are are used in place of the MX2 and MSP2 options.

  • Page 29: 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 30 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 31: 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 32: 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 33: 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 34 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 35: 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 36: Description And Installation Of Optional Control Box Panels

    DESCRIPTION AND INSTALLATION OF OPTIONAL CONTROL BOX PANELS A number of Optional Features are available for use with Power Feed 10. Some Installation information is provided in this section. REFER TO THE INSTRUC- TIONS THAT COME WITH EACH KIT FOR DETAILED INFORMATION REGARDING INSTALLA- TION.
  • Page 37 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 38 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, burnback, postflow, and spot time. Descriptions Indicator Lights - Extra bright red LEDʼs for viewing at almost any angle.
  • Page 39 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, burnback, postflow and spot time.
  • Page 40 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 stickout of the electrode.
  • Page 41 SAVE - The save mode allows “hard” memories to be changed. Pressing the SAVE key will light the save indicator, and enter the save mode. In the save mode, the indicator for the memory that was the source of the active procedureʼs contents will blink, whether their contents are still equal or not.
  • Page 42 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 43 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 44: Guns And Gun Adapters

    C-10 GUNS AND GUN ADAPTERS The Power Feed 10 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 has been designed to make connect- ing a variety of guns easy and inexpensive with the K1500 series of gun connection kits.

  • Page 45: 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 46 C-12 K590-5 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 47: 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 48: 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 49: 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 50 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 51 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 52 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 Box 9.
  • Page 53 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 54 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 55 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 Circuit Boards 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 56 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 Circuit Boards). Status lights are solid green on Circuit Boards and Head boards. 18. Wire feed speed is consistent and adjustable, but operates at the wrong speed.
  • Page 57 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 58 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 59 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 60: Power Feed

    DIAGRAMS 512C 500C POWER FEED 10 500D 540D 542D 541D...
  • Page 61 540A 500A 542A 400A 541A DIAGRAMS POWER FEED 10...
  • Page 62 DIAGRAMS POWER FEED 10...
  • Page 63 NOTES POWER FEED 10...
  • Page 64 NOTES POWER FEED 10...
  • Page 65 NOTES POWER FEED 10...
  • Page 66 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 67 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 68 • 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...

This manual is also suitable for:

Power feed 10

Table of Contents