Lincoln Electric POWER FEED IM916 Operator's Manual
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Lincoln Electric POWER FEED IM916 Operator's Manual

Lincoln Electric POWER FEED IM916 Operator's Manual

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IM916
Power Feed 10M Dual Wire Feeder
July, 2010
For use with: Power Feed™ 10M Dual Wire Feeder: Code 11378
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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  • Page 1 RETURN TO MAIN MENU IM916 Power Feed 10M Dual Wire Feeder July, 2010 For use with: Power Feed™ 10M Dual Wire Feeder: Code 11378 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 ...

  • 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 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 Electrode Routing...A-2 Control Cable ...A-2 Control Cable Connections ...A-2 Control Cable Specifications, Availiable Cable Assemblies ...A-2 Output Cable, Connections and Limitations ...A-3 Negative Electrode Polarity ...A-3 Electrode Sense Polarity, To Set The Electrode Sense Polarity Switch ...A-3 Voltage Sensing ...A-4 Wire Drive Gear Ratio (High or Low Speed) ...A-5 Selecting the Proper Gear Ratio ...A-5...
  • Page 8 Maintenance ...Section D Safety Precautions ...D-1 Routine Maintenance ...D-1 Avoiding Wire Feeding Problems ...D-1 Periodic Maintenance...D-1 Procedure for Removing Feedplate from Wire Feeder ...D-1 ________________________________________________________________________________ Troubleshooting ...Section E Safety Precautions ...E-1 Troubleshooting Guide ...E-2 thru E-12 ________________________________________________________________________________ Diagrams ...Section F Wiring (Power Feed 10 Dual Head) ...F-1 Control Box Dimension Print...F-2 Bench Model Dimension Print...F-3...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS – Power Feed™ 10M Dual Wire Feeder WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO Speed K2234-3 Bench Model 50-800 IPM K2316-1 Boom Model (1.27-20.3 m/m) CONTROL bOx, WIRE DRIVE AND COMPLETE UNITS SPEC.# TYPE INPUT 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: Output Cable, Connections And Limitations

    OUTPUT CAbLES, CONNECTIONS AND LIMITATIONS Connect a work lead of sufficient size and length (Per Table A.1) between the proper output terminal 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 12: Voltage Sensing

    Depending upon the process, inductance within the electrode and work lead cables can influence the volt- age apparent at the studs of the welder. Voltage sense leads improve the accuracy of the arc condi- tions and can have a dramatic effect on performance.

  • Page 13: Wire Drive Gear Ratio (High Or Low Speed

    Work Voltage Sensing The standard Power Wave® 455’s default to the work stud (work sense lead disabled) For processes requiring work voltage sensing, con- nect the (21) work voltage sense lead (K940) from the Power Wave® work sense lead receptacle to the work piece.

  • Page 14: Changing The Wire Drive Ratio

    CHANGING THE WIRE DRIVE GEAR RATIO Changing the ratio requires a gear and a dip switch setting change. The Power Feed™ Wire Feeders are shipped with both high speed and a low speed gears. As shipped from the factory, the low speed (high torque) gear is installed on the feeder.

  • Page 15: Wire Feed Drive Roll Kits

    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 section. The electrode sizes that can be fed with each roll and guide tube are stenciled on each part.

  • Page 16: General Gun Connection Guidelines

    • 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 17: Wire Spindle Placement

    WIRE SPINDLE PLACEMENT The reel stand provides two mounting locations for the 2 inch diameter wire reel spindle to accommodate var- ious reel sizes. Each mounting location consists of a tube in the center of the reel stand, and locating slots on the outside of the reel stand.

  • Page 18: 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 configure...

  • Page 19: Operation

    SAFETY PRECAUTIONS Read entire Operation section before operating the Power Feed™ 10M Dual Wire Feeder. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. •...

  • Page 20: Product Description

    PRODUCT DESCRIPTION The Power Feed™ 10M Dual Wire Feeder unit con- sists of a user interface and two wire drives. This unit will be available as a bench model or a boom model. The Power Feed™ 10M Dual Wire Feeder is a high performance, digitally controlled, modular wire feeder.

  • Page 21: Operational Features And Controls

    OPERATIONAL FEATURES AND CONTROLS POWER FEED™-10M SERIES SYSTEM CONFIGURA- TION The specific system component function of the pc board will be configurable by dip switch or by software configuration tool. Dip switch configuration is as follows: Refer to DIP switch settings of figures below. Notes: 1.

  • Page 22: Output Controls

    3. OUTPUT CONTROLS • The Power Feed™ 10M Dual Wire Feeder has 2 encoder knobs to adjust weld parameters. • Each encoder changes the displayed value of the meter located directly above that encoder. • In CC-GTAW modes when equipped with a foot or hand amptrol, the left encoder sets the maximum welding current.

  • Page 23: Layout-Controls

    LAYOUT-CONTROLS (SEE FIGURE b.3) The MSP4 panel controls (Items 7 and 9) set consist of an encoder knob Item 8 and two push buttons. The encoder is primarily used to change the value of the selected attribute. The left pushbutton (Item 7) is used to toggle between Weld Mode selection and any active Arc Controls (a.k.a.

  • Page 24: Machine Setup/User Preferences

    This allows wireless machine configuration using a Palm OS based hand held computer. A proprietary Palm OS application, ALPalm, was developed for this purpose. (Contact Lincoln Electric for more information on this fea- ture.) LOCKOUT/SECURITY The MSP4 can be optionally configured to prevent the welder from changing selected MSP4 options.

  • Page 25: Set-Up Feature Menu

    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 26: User Defined Parameters

    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 27 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 28 b-10 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 29 b-11 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 30 b-12 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 31 b-13 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 32 b-14 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.
  • Page 33 b-15 Head / Procedure Select • Press to select head or change active procedure. • Changes to weld settings affect active procedure only. HEAD 1 PROCEDURE Proce dure A -Weld Parameters -Mode -Preflow/Post flow -Run in -Start Parameters -Arc Control -Crater Parameters -Burnb ack Procedure B...

  • Page 34: Dual Head/Dual Procedure With Memory

    b-16 Each procedure contains/stores the following informa- tion: • Basic weld parameters as applicable - WFS, Volts, Trim, Amps • Weld Mode - Mode Number • Preflow/Postflow - Time in Seconds • Run in - WFS Only (work point determined by next active sequence state) •...

  • Page 35: Step / 4 Step Operation

    b-17 Recalling from Memory To recall the contents of a memory into the active proce- dure, momentarily push the desired memory button (for less than 2 seconds). The saved parameters will be copied into the active procedure, and the LED of the memory button will light indicating the source of the infor- mation.

  • Page 36: Cold Feed/Gas Purge Switch

    b-18 4 Step Synergic Operation: Without Start/Crater/burnback functions active Waveform Functionality: 1. Trigger is pulled and released; Preflow sequence begins and runs until Preflow timer expires. 2. Run-In sequence begins and runs until Arc is estab- lished 3. Arc established; Weld sequence begins. 4.

  • Page 37: Hot Inch

    b-19 HOT INCH Hot inch occurs when the trigger is pulled and an arc is not established. After a 2.5 second period, the Sequencer will jump to the Weld state and the wire feeder will run at the preset wire feed speed on the display.
  • Page 38 b-20 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 39: Feeding Electrode And Brake Adjustment

    POWER FEED™ 10M DUAL WIRE FEEDER 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 40: Making A Weld

    b-22 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 41: Component Status Lights

    b-23 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 42 b-24 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.

  • Page 43: Limit Settings

    b-25 LIMIT SETTING Each user memory can be optionally configured to limit the user’s range of control over some user interface set- tings. By default, user limits are not enabled. To set lim- its for a selected memory, first select a weld mode and perform a memory save.

  • Page 44: 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 45: Field Installed Options/Accessories

    FIELD INSTALLED OPTIONS/ACCESSORIES • OPTIONAL CONTROL PANEL KITS • Arclink Cables - Without Weld Cable Cable Lengths: 8 ft 16 ft 25 ft 50 ft 100 ft • Co-Axial Power Cable Cable Length: 25 ft. (350 amps) 50 ft. (350 amps) 75 ft.

  • Page 46: Guns And Gun Adapters

    K435 - COIL ADAPTER Permits 14 lb. (6 kg) Innershield coils to be mounted on 2” (51 mm) O.D. spindles. K363P - READI-REEL ADAPTER Adapts Lincoln Readi-Reel coils of electrode 30 lb. (14 kg) and 22 lb. (10 kg) to a 2” (51 mm) spindle. Durable molded plastic one piece construction.

  • Page 47: Dual Procedure Switch Options

    K1500-4 (MILLER CONNECTION) For any gun having a newer style Miller connector. Install gun adapters per the instructions shipped with K1500-5 (OxO CONNECTION) For any gun having an OXO style connector. Install gun adapters per the instructions shipped with it. CONDUIT ADAPTERS K1546-2 ADAPTER for use with Lincoln Magnum conduit and E-Beam...

  • Page 48: Making A Weld With The Prince Xl Or Cobra Gold Torch Installed

    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” by reducing surge caused by excess pressure in supply hose. Install the 5/8-18 male outlet of the regulator to the 5/8- 18 female gas inlet on the back panel of the wire drive.

  • Page 49: 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 50: How To Use 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 51 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Rough wire feeding or wire not feed- ing 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 52: Troubleshooting

    Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Variable or “hunting” arc. 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 53 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Tip seizes in diffuser. 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 54 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Speed does not change when weld current flows. Status lights are solid green. Voltmeter and/or ammeter do not function properly even though status lights are solid green. Welding may vary from normal procedure. Purge switch on feed head does not activate solenoid but trigger closure in MIG or pulse modes does.
  • Page 55 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Displays and/or indicator lights do not change when their correspond- ing switches and or knobs are acti- vated to request a change. Display(s) and status lights are blank. Dual Procedure is not functioning when using remote dual procedure switch.
  • Page 56 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455: Code 10555 and below Note: For any Err # listed below write down the error number for reference and try cycling power to see if the error clears itself.
  • Page 57 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455: Code 10555 and below Note: For any Err # listed below write down the error number for reference and try cycling power to see if the error clears itself.
  • Page 58 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455: Code 10555 and below Note: For any Err # listed below write down the error number for reference and try cycling power to see if the error clears itself.

  • Page 59: Error Codes For The Power Wave

    E-10 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455: Code 10675 and above. ERROR CODES FOR THE POWER WAVE 455 The following is a list of possible error codes that the Power Feed™ 10M Dual Wire Feeder can output via the display on this user interface.
  • Page 60 E-11 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455: Code 10675 and above. ERROR CODES FOR THE POWER WAVE 455 The following is a list of possible error codes that the Power Feed™ 10M Dual Wire Feeder can output via the display on this user interface.
  • Page 61 E-12 Observe all Safety Guidelines detailed throughout this manual Error Codes for the Power Wave 455: Code 10675 and above. ERROR CODES FOR THE POWER WAVE 455 The following is a list of possible error codes that the Power Feed™ 10M Dual Wire Feeder can output via the display on this user interface.

  • Page 62: Diagrams

    DIAGRAMS POWER FEED™ 10M DUAL WIRE FEEDER...
  • Page 63 DIAGRAMS POWER FEED™ 10M DUAL WIRE FEEDER...
  • Page 64 POWER FEED™ 10M DUAL WIRE FEEDER DIAGRAMS...
  • Page 65 DIAGRAMS POWER FEED™ 10M DUAL WIRE FEEDER...
  • 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...

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Power feed 10m

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