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IM9 5
RETURN TO MAIN MENU
July, 2010
POWER FEED 10M SINGLE WIRE FEEDER
11377
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 thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
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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Related Manuals for Lincoln Electric POWER FEED IM915
Summary of Contents for Lincoln Electric POWER FEED IM915
- Page 1 IM9 5 RETURN TO MAIN MENU July, 2010 POWER FEED 10M SINGLE WIRE FEEDER 11377 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 ...
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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 SAFETY...
- Page 4 SAFETY...
- 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 Thank You...
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Page 7: Table Of Contents
Installation...Section A Technical Specifications...A-1 Safety Precautions ...A-2 Location...A-2 Mounting ...A-2 Safety Precautions ...A-2 Weld Cable Sizing ...A-2 Weld Cable Connection ...A-2 Coaxial Weld Cables ...A-3 Weld Cable Sizes ...A-3 Changing Electrode Polarity ...A-4 Negative Electrode Polarity ...A-4 Cables ...A-5 Digital Control Cable ...A-5 Welding gun/Wire Feeder Trigger Connector ...A-5 Wire Drive Systems ...A-6 Changing Drive Rolls and Wire Guides...A-6... - Page 8 Operation...Section b Aluminum Synergic GMAW-P (Pulsed MIG) and GMAW-PP (Pulse on Pulse) Welding ...B-23 Machine Functionality by Weld Process ...B-24 thru B-29 GTAW (TIG) Welding ...B-29 Weld Mode Searching ...B-30 User Memories ...B-30 6. Optional Dual Procedure/Memory Panel Operation ...B-31 Limit Settings ...B-31, B-32 Accessories ...Section C General Options / Accessories...C-1 Thru C-3...
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Page 9: Installation
TECHNICAL SPECIFICATIONS : Power Feed™ 10M Single Wire Feeder WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO Low Speed K2230-2 Bench Model 50-800 IPM (1.27-20.3 m/m) CONTROL bOx, WIRE DRIVE AND COMPLETE UNITS SPEC.# TYPE INPUT POWER K2230-2 Wire Drive &... -
Page 10: Safety Precautions
SAFETY PRECAUTION ELECTRIC SHOCK can kill. • Only qualified personnel should perform 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 working on this equipment. -
Page 11: Coaxial Weld Cables
CAUTION Excessive voltage drops caused by poor work piece connections often result in unsatisfactory welding performance. ------------------------------------------------------------------------ COAxIAL WELD CAbLES Coaxial welding cables are specially designed welding cables for STT™ and pulse welding. cables feature low inductance, allowing fast changes in the weld current. -
Page 12: Changing Electrode Polarity
CHANGING ELECTRODE POLARITY SETTING The Power Feed™ 10M Single Wire Feeder is preset at the factory for Electrode Positive welding. (See Figure A.3) NOTE: Changing this DIP Switch does not change the actual welding polarity. The actual welding polarity is changed by reversing the welding cables at the power source output studs. -
Page 13: Cables
CAbLES Digital Control Cable, K1543-xx ArcLink/LincNet control cables are special high quality cables for digital communication. The cables are cop- per 5 conductor cable in a SO-type rubber jacket. There is one 20 gauge twisted pair for network com- munications. This pair has an impedance of approxi- mately 120 ohms and a propagation delay per foot of less than 2.1 nanoseconds. -
Page 14: Wire Drive Systems
WIRE DRIVE SYSTEMS Drive Roll Kits are designed to feed specific types and wire sizes. The Power Feed™ 10M Single Wire Feeder does not include these Drive Roll Kits with this Wire Drive, but are available for ordering from the fol- lowing tables: Drive Roll Kits, Steel Wires Includes: 4 Smooth V groove drive rolls and an inner... -
Page 15: Drive Roll Pressure Setting
Set the drive roll pressure by: 1. Press the end of the 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" or jams, the drive roll pres- sure is too high. -
Page 16: Welding Gun Torch And Accessories
WELDING GUNS, TORCHES AND ACCES- SORIES GUN RECEIVER bUSHING The Power Feed™ 10M Single Wire Feeder comes with a K1500-2 gun receiver bushing, for use with the Magnum gun with a K466-10 connector kit. MAGNUM GUN AND CAbLE ASSEMbLIES The Power Feed™ 10M Single Wire Feeder model will accept a number of optional gun and cable assemblies. -
Page 17: Wire Feed Shut Down Circuit
WIRE FEED SHUT DOWN CIRCUIT The wire feed shut down circuit is used to stop the wire feed in the event of a fault. The most common use of the circuit is with water cooled guns. A flow sensor is connected to the circuit to protect the weld- ing gun if the water flow is interrupted. -
Page 18: Wire Reel Loading
A-10 S C R E W F O R R O T A T I N G F E E D P L A T E H I G H S P E E D L O W S P E E D S C R E W S E T T I N G S C R E W S E T T I N G C L A M P I N G C O L L A R S C R E W S... - Page 19 A-11 Using K1504-1 Coil Reel 50-60 lb. (22.7 - 27.2 kg) Coil Mounting (See Figure A.10) 1. Make sure the spindle of the wire reel stand is in the upper position. 2. With the coil reel assembly mounted to a 2" (51mm) spindle, loosen the spinner nut and remove the cover plate.
- Page 20 A-12 Loading 30 lb. (13.6 kg) Readi-Reels (See Figure A.11) A K363-P Readi-Reel adapter is required for loading these spools on 2" (51mm) spindles. 1. Squeeze the release bar on the retaining collar and remove it from the spindle. 2. Place the Readi-Reel adapter on the spindle, align- ing the spindle brake pin with one of the holes in the adapter.
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Page 21: Shielding Gas Connection
• Keep the cylinder away from all areas where it may be damaged. • Never lift the welder with cylinder attached. • Never allow the welding electrode to touch cylinder. • Keep the cylinder away from welding or other live electrical circuits. -
Page 22: Examples Of Connecting An Arclink Power Wave System
The majority will self configure. If an assembled system flashes the sta- tus light green rapidly on all components, contact the Lincoln Electric Company for further assistance. Current Power Feed 10M models that will not self con- figure... -
Page 23: Operation
• Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not use AC welder if your cloth- ing, gloves or work area is damp or if working on, under or inside work- piece. -
Page 24: Product Description
PRODUCT DESCRIPTION General Physical Description The Power Feed™ 10M Single Wire Feeder is a mod- ular wire feeder, consisting of two components - a wire drive and a control box - are available assem- bled as a bench unit or as a boom system. High speed, highly reliable digital cables connect the com- ponents together and to the Power Wave power source. -
Page 25: Bench Model Features
bASIC Power Feed™ 10M Single Wire Feeder WELDING SYSTEM CONFIGURATION CV Welding: Pulse Welding or STT Welding: POWER FEED™ 10M SINGLE WIRE FEEDER OPERATION bENCH MODEL FEATURES... -
Page 26: Front Panel Controls And Connections
FRONT PANEL CONTROLS AND CONNECTIONS CASE FRONT CONTROLS ITEM Status LED indicates system status. Digital Meter Display is a bright LED display of key welding information. Adjusting Parameter Knobs. MSP4 Panel is used to set the weld mode, adjust the arc, change arc start/end parameters and for set-up information. -
Page 27: Status Led
1. STATUS LED The status LED indicates system status. Normal operation is a steady green light. Note: During normal power-up, the LED may flash red and/or green as the equipment performs self tests. LED condition Definition Steady green System okay. The power source and wire feeder are communicating nor- mally. -
Page 28: Synergic Cv Voltage Display
b. VOLTS / TRIM DISPLAY The voltage/trim meter displays either the voltage or trim value, depending upon the welding process (mode) being used and the status of the wire feeder and power source. PRIOR TO WELDING Weld Process Volts / Trim Display prior to operation Nonsynergic CV Displays the preset Voltage value. -
Page 29: Overview
OVERVIEW: The MSP4 is the standard mode select panel for the Power Feed™ 10M Single Wire Feeder wire feeders. The MSP4 is capable of: - Weld mode selection. - Arc Control adjustment. - Weld sequence control (Preflow Time, Run-in WFS, etc.) FIGURE B.3 IR PORT PULSE 4043 Ar... -
Page 30: Power-Up Sequence
This allows wireless machine configuration using a Palm OS based hand held computer. A proprietary Palm OS application, Weld Manager, was developed for this pur- pose. (Contact Lincoln Electric for more information on this feature.) LOCKOUT/SECURITY The MSP4 can be optionally configured to prevent the welder from changing selected user interface controls. -
Page 31: Limit Setting
LIMIT SETTING The MSP4 can be optionally configured to limit the opera- tor’s range of control of any weld parameter (weld WFS, arc control, etc.). Limits are only available with the Dual Procedure/Memory Panel. MACHINE SETUP/USER PREFERENCES The MSP4 can be used to configure and troubleshoot the machine. -
Page 32: Setup Features Menu
b-10 The Setup Menu gives access to the Setup Configuration. Stored in the setup configuration are user parameters that generally only need to be set at installation. The parameters are grouped as shown in the following table. PARAMETER P.1 through P.99 P.100 through P.107 SET-UP FEATURES MENU (See Figure B.3a) - Page 33 b-11 Parameter Exit Setup Menu This setup menu parameter can be used to exit the setup menu. When P.0 is displayed, press the left Mode Select button to exit the setup menu. Wire Feed Speed Units This option selects which units to use for displaying wire feed speed. English = inches/minute wire feed speed units (default).
- Page 34 b-12 Parameter Procedure Change Method This option selects how remote procedure selection (A/B) will be made. The selected procedure can be changed locally at the user interface by pressing the 'A-Gun-B' button. The following methods can be used to remotely change the selected procedure: * Use an external switch wired to the procedure select input.
- Page 35 b-13 Parameter Gun Offset Adjustment This option adjusts the wire feed speed calibration of the pull motor of a push-pull gun. This should only be performed when other possible corrections do not solve any push-pull feeding problems. An rpm meter is required to perform the pull gun motor offset calibration. To perform the calibration procedure do the following: 1.
- Page 36 b-14 Parameter P.16 Push-Pull Gun Knob behavior This option determines how the potentiometer on the Push/Pull torch will behave. Gun Pot Enabled = The welding wire feed speed is always controlled by the potentiometer on the push- pull gun (default). The left front panel knob is only used to adjust Start and Crater wire feed speed. Gun Pot Disabled = The wire feed speed is always controlled by the left front panel knob.
- Page 37 b-15 Parameter P.99 Show Test Modes Most power sources contain weld modes used for calibration and test purposes. By default, the machine does not include test weld modes in the list of weld modes that are available to the operator. To manually select a test weld mode, set this option to "Yes".
- Page 38 b-16 Parameter P.501 Encoder Lockout Locks one or both of the upper knobs (encoders), preventing the operator from changing wire feed speed, amps, volts or trim. The function of each upper knob depends on the selected weld mode. When a costant current weld mode is selected (e.g.
- Page 39 b-17 Parameter P.506 Set User Interface Passcode Prevents unauthorized changes to the equipment. The default passcode is zero which allows full access. A nonzero passcode will prevent unauthorized: changes to memory limits, saving to memory (if P.502 = Yes), changes to setup parameters (if P.505 = Yes). This parameter can only be accessed using Power Wave Manager software.
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Page 40: Cold Feed / Gas Purge Switch
b-18 4. COLD FEED / GAS PURGE SWITCH Cold Feed and Gas Purge are combined into a two position momentary toggle switch. To activate Cold Feeding, hold the switch in the UP position. The wire drive will feed electrode but neither the power source nor the gas solenoid will be energized. - Page 41 b-19 2 STEP TRIGGER OPERATION (See Figure B.4) Sometimes it is advantageous to set specific arc start, crater and arc ending parameters for the ideal weld. Many times when welding aluminum crater control is necessary to make a good weld. This is done by set- ting Start, Crater and Burnback functions to desired values.
- Page 42 Start and less heat desired during Crater. With 4 step trigger, the welder chooses the amount of time to weld at the Start, Weld and Crater settings by using the gun trigger. Burnback reduces the likelihood of wire to sticking in the weld pool at the end of a weld and also prepares the end of the wire for the next arc start.
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Page 43: Process Setup And Operation
b-21 PROCESS SETUP AND OPERATION The Power Feed/Power Wave system delivers world class arc performance for a wide variety of processes. Using the foundation of Waveform Control Technology™, each weld mode is precisely tuned to meet exacting standards for low spatter, weld bead profile and arc shape. -
Page 44: Steel And Stainless Synergic Gmaw-P (Pulsed Mig) Welding
b-22 STEEL AND STAINLESS SYNERGIC GMAW-P (PULSED MIG) WELDING Synergic GMAW-P (Pulsed MIG) welding is ideal for low spatter, out of position and reduced heat input applica- tions. During pulse welding, the welding current continuously switches from a low level to a high level and then back again. -
Page 45: Aluminum Synergic Gmaw-P (Pulsed Mig)And Gmaw-Pp (Pulse On Pulse) Welding
b-23 ALUMINUM SYNERGIC GMAW-P (PULSED MIG)AND GMAW-PP (PULSE ON PULSE) WELDING The Power Feed™ 10M Single Wire Feeder and Power Wave welding power source combine to readily produce top quality aluminum welds with excellent appearance, little spatter and good bead shape. Push- pull guns are available for consistent feeding when welding a long distance away from the wire feeder. -
Page 46: Machine Functionality By Weld Process
b-24 MACHINE FUNCTIONALITY bY WELD PROCESS CC-STICK Use the following tables to review how the machine functions (output controls, arc control and weld options) for the weld modes listed in the top table. ARC CONTROL ARC FORCE DESCRIPTION (Soft)-10.0 to Arc Force adjusts the short cir- (Crisp)+10.0 cuit current for a soft arc, or for... - Page 47 b-25 MACHINE FUNCTIONALITY bY WELD PROCESS CV GMAW/FCAW (NON-SYNERGIC) Use the following tables to review how the machine functions (output controls, arc control, Start options and weld options) for the weld modes listed in the top table. OUTPUT CONTROL KNObS, WELD MODE 5 & 6 AMPS LESS MORE...
- Page 48 b-26 MACHINE FUNCTIONALITY bY WELD PROCESS GMAW (SYNERGIC) Use the following tables to review how the machine functions (output controls, arc control, Start options and weld options) for the weld modes listed in the top table. MATERIAL Steel Steel Stainless Stainless Aluminum 4043 Aluminum 5356...
- Page 49 b-27 MACHINE FUNCTIONALITY bY WELD PROCESS PULSE AND PULSE-ON-PULSE (SYNERGIC) Use the following tables to review how the machine functions (output controls, arc control, Start options and weld options) for the weld modes listed in the top table. MATERIAL ALUMINUM 4043 ALUMINUM 4043 ALUMINUM 5356 ALUMINUM 5356...
- Page 50 b-28 MACHINE FUNCTIONALITY bY WELD PROCESS STT AND STT II (NONN-SYNERGIC) Use the following tables to review how the machine functions (output controls, arc control, Start options and weld options) for the weld modes listed in the top table. G MA W-S T T WE L D MODE MA T E R IA L G A S 0.035 0.045 0.052...
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Page 51: Gtaw (Tig) Welding
b-29 MACHINE FUNCTIONALITY bY WELD PROCESS GTAW (Touch Start TIG) Welding Use the following tables to review how the machine functions (output controls, arc control, Start options and weld options) for the weld modes listed in the top table. ARC CONTROL No Arc Controls are active for Touch Start TIG. -
Page 52: Weld Mode Searching
b-30 WELD MODE SEARCHING The Weld Mode Search feature allows the selection of a welding mode based on certain criteria (wire size, process type, etc.). SEARCHING FOR A WELD MODE To search for a mode, turn the control knob until “Weld Mode Search”... -
Page 53: Optional Dual Procedure/Memory Panel Operation
b-31 6. OPTIONAL DUAL PROCEDURE/MEMORY PANEL OPERATION The Dual Procedure/Memory Panel performs three functions: • Weld procedure selection • Memory save and recall • Limits setting There are two procedure memories (A and B) and six user memories (1-6). Procedure Memory vs. User Memory Procedure memory is used while welding. - Page 54 b-32 One of these four items will blink to indicate which item will change when the Mode Select Panel Knob is rotated. Initially, the selected item will be the attribute. To select the high limit, press either Mode Select Panel button and the high limit value will begin to blink.
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Page 55: Accessories
OPTIONAL: K2339-1 K2429-1 ArcLink “T” Cable Connector K2360-1 Dual Procedure/Memory Panel K1543-xx K1796-xx K1842-xx K1500-1 Gun Receiver Bushing (for guns with K466-1 Lincoln gun connec- tors; Innershield and Subarc guns) K1500-2 Gun Receiver Bushing (for guns with K466-2, K466-10 Lincoln gun connectors;... - Page 56 K1500-4 Gun Receiver Bushing (for gun with K466-3 Lincoln gun connec- tors; compatible with Miller® guns.) K1500-5 Gun Receiver Bushing (compatible with Oxo® guns.) K489-9 Gun Receiver Bushing (for Lincoln Fast-Mate guns.) K466-2 Magnum 200/300/400 to K1500-2 Adapter K613-7 Magnum 550 to K1500-3 Adapter K1546-1 Incoming Bushing, Lincoln Conduit .025- 1/16"...
- Page 57 K162-1 Spindle Adapter, for Readi-Reels K435 Spindle Adapter, for mounting 14 lb. Innershield Coils on 2" spindles. K468 Spindle Adapter, for mounting 8" K363P Readi-Reel Adapter, for mounting K438 Readi-Reel Adapter, for mounting K1504-1 Coil Adapter, for mounting 50-60 K1634-3 Plastic Wire Cover for 30-44 lb.
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Page 58: 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 59: Troubleshooting
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 60 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) LINC-NET SYSTEM ERROR CODES Err 006 Err 100 ARCLINK SYSTEM ERROR CODES Err 31 Primary overcurrent Err 32 Capacitor bank "A" under voltage. 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 61 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) ARCLINK SYSTEM ERROR CODES Err 33 Capacitor bank "B" under voltage. Err 34 Capacitor bank "A" overvolt- age. Err 35 Capacitor bank "B" overvolt- age. Err 41 Long term secondary over- current.
- Page 62 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) ARCLINK SYSTEM ERROR CODES Err 44 Main CPU problem. Err 53 Voltage sense loss. Err 54 Short term secondary over- current. Err 81 Motor overload, long term. Err 82 Motor overload, short term. Err 95 Spool gun or pull gun motor overload.
- Page 63 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) OUTPUT PRObLEMS The feeder does power up - no dis- play, no cold feed. No shielding gas. Gas solenoid not operating properly or intermittent. 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 64 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Inconsistent wire feeding or wire not feeding but drive rolls 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 65 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Wire feed speed consistently oper- ates at the wrong value. Variable or "hunting" arc. Poor arc starts with sticking or "blast-offs", weld porosity, narrow and ropy looking bead. 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 66 DIAGRAMS POWER FEED™ 10M SINGLE WIRE FEEDER...
- Page 67 DIMENSION PRINT POWER FEED™ 10M SINGLE WIRE FEEDER...
- Page 68 NOTES POWER FEED™ 10M SINGLE WIRE FEEDER...
- Page 69 NOTES POWER FEED™ 10M SINGLE WIRE FEEDER...
- Page 70 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
- Page 71 Spanish PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 72 • 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...