A-2
INSTALLATION
POWER FEED™ 10A CONTROLLER
A-2
SAFETY PRECAUTION
WELDING VOLTAGE
Wire feed parts are electrically live while welding and while
inching wire (with Touch Sense feature selection). The elec-
trically live parts are listed below:
Electrode
Electrode Reel
Wire Drive Motor
Drive Rolls
Gear Box
Cross-seam Adjuster
Wire Straightener
Welding Nozzle
Welding Cables
Welding Cable Terminal
• Do not touch electrically live parts or elec-
trodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
MECHANICAL HAZARDS
• Welding fixture or wire feeder will move during weld-
ing or inching. Keep away from pinch points.
• Electrode reel and drive rolls turn during
welding or inching. Keep gloved hands
away from areas that may catch the glove.
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LOCATION AND MOUNTING
The POWER FEED™ 10A CONTROLLER will operate in
harsh environments. Even so, it is important that simple pre-
ventative measures are followed in order to assure long life
and reliable operation. The POWER FEED™ 10A CON-
TROLLER must be located where there is little risk of
impacts to the Controller.
ELECTRIC SHOCK can kill.
• Only a qualified electrician should
connect the POWER FEED™ 10A
CONTROLLER. Installation should
be made in accordance with the
appropriate National Electrical
Code, the local codes and the infor-
mation in this manual.
• 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.
• Do not touch electrically hot parts.
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HIGH FREQUENCY PROTECTION
Locate the POWER FEED™ 10A CONTROLLER away from
radio controlled machinery. The normal operation of the
POWER FEED™ 10A CONTROLLER may adversely affect
the operation of RF controlled equipment, which may result
in bodily injury or damage to the equipment.
AUXILIARY EQUIPMENT INPUT POWER CON-
NECTION
The POWER FEED™ 10A CONTROLLER has the ability to
control auxiliary equipment such as flux hoppers and travel
motors using solid state relays. There are three relays in the
POWER FEED™ 10A CONTROLLER, controlled by two
independent coil drivers. The coils of CR1 and CR2 are in
parallel, therefore, they must turn ON and OFF at the same
time. The CR1 and CR2 relays are designated for driving
travel motors to control motion. CR3 is driven separately,
and is designated to control flux hopper operation.
POWER FEED™ 10A CONTROLLER Relay Ratings:
Coil: 12Vdc, resistance = 86 ohms at 25° C
N.C. Contacts: 3A @ 277Vac
N.O. Contacts: 30A @ 277Vac
The POWER FEED™ 10A CONTROLLER does not provide
the input power to feed auxiliary equipment, therefore a sep-
arate power feed must be provided by the end user. The
POWER FEED™ 10A CONTROLLER has been shipped
standard with all of the wiring and connectivity to connect to
the Lincoln K325 TC-3 Travel Carriage (4-pin cable connec-
tor) and the Lincoln K219 Automatic Flux Hopper (3-pin
cable connector). The CR2 Relay is wired to the 4-pin travel
connector, and the CR3 Relay is wired to the 3-pin flux con-
nector, both located on the bottom of the POWER FEED™
10A CONTROLLER. 115Vac, 50/60Hz power is required for
the Lincoln auxiliary equipment.
If either of these is to be used with the POWER FEED™
10A CONTROLLER, the end-user must provide the 115Vac
input power to the terminal strip located inside the POWER
FEED™ 10A CONTROLLER. Access to the terminal strip
may be obtained via the 4 access holes in the bottom of the
POWER FEED™ 10A CONTROLLER. These access holes
are shipped with plug buttons installed.
Although input power to POWER FEED™ 10A CON-
TROLLER is turned off, the customer installed auxiliary
input may be energized! Ensure that all input power to
the POWER FEED™ 10A CONTROLLER is turned off
before opening the cover.
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WARNING
WARNING
CAUTION
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