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ii

SAFETY

ii

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

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.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of

electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. 

When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5. b.  The operation of welding fume control equipment is affected

by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved.  Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors

coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

Содержание IM658-A

Страница 1: ...THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with Power Feed 10 Dual Wire Drive Bo oom Mount Code 10625 10788 Power Feed 10 Dual Boom P...

Страница 2: ...WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of...

Страница 3: ...er for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both...

Страница 4: ...easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site sp...

Страница 5: ...appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paiss...

Страница 6: ...mportant when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the...

Страница 7: ...nection A 10 General Gun Connection Guidelines A 11 GMAW Shielding Gas A 12 Gas Guard Regulator A 12 Wire Spindle Placement A 12 Water Connections For Water Cooled Guns A 12 Wire Feed Shut Down Circui...

Страница 8: ...ecautions 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...

Страница 9: ...ower Feed 50 800 IPM 025 3 32 in 035 125 in 75 1200 IPM 025 1 16 in 035 5 64 in 2 3 10 Dual 1 27 20 3 m m 0 6 2 4 mm 0 9 3 2 mm 2 03 30 5 m m 0 6 1 6 mm 0 9 2 0 mm Boom Package K1686 1 Power Feed 50 8...

Страница 10: ...iety of configurations A boom model feeder is shipped from the factory separated from the Wire Drive with the necessary receptacles installed In the case of a bench model feeder the Control Box can be...

Страница 11: ...alling an output receptacle in a Wire Drive use K1549 1 and an input receptacle in a Control Box use K1550 1 This sys tem would meet the rule stated above This means that the first component in the sy...

Страница 12: ...on poor arc starting and low wire driving force wire feeding problems Lincoln control cables are copper 5 conductor cable in a SO type rubber jacket There is one 20 gauge twist ed pair for network com...

Страница 13: ...e Power Feed 10 Dual wire drive can be easily and quickly changed by changing the external drive gear The Power Feed 10 Dual is shipped with both a high speed and a low speed gear As shipped from the...

Страница 14: ...o line up further loosen the screw on right face of feed plate 5 Remove the small gear from the output shaft Lightly cover the output shaft with engine oil or equivalent Install gear onto output shaft...

Страница 15: ...owing 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 4 Run in Mi...

Страница 16: ...onfiguration 4 Power Feed 10 Dual Dual Power Feed 11 5 Procedure Change with Trigger OFF Procedure Change with Trigger ON 6 Set lower limits 7 Set upper limits 8 Must be on for all units Permits selec...

Страница 17: ...oup 2 Network Group ID LSB Assigns Wire Drive to a specific group 3 Network Feed Head ID MSB Assigns feed head number to wire drive 4 Network Feed Head ID Assigns feed head number to wire drive 5 Netw...

Страница 18: ...ection 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...

Страница 19: ...d to the Power Feed by using one of the K1500 series adapter kits See Gun Adapters in ACCESSORIES section GENERAL GUN CONNECTION GUIDELINES The instructions supplied with the gun and K1500 series gun...

Страница 20: ...nd 572 Refer to the instruc tions that come with flow sensor kit for detailed instal lation instructions GMAW SHIELDING GAS Customer must provide a cylinder of shielding gas a pressure regulator a flo...

Страница 21: ...wo panels to be interchanged Instead of the upper middle and lower panels being large small and large they could be installed in the order small large large This may be done for convenience sake or to...

Страница 22: ...ctrical Code or any applicable local codes Only qualified personnel should perform this installation WARNING RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Feed Wire Feeders can b...

Страница 23: ...All selections are done with push buttons and indicator lights To select the feed head to be used simply press the desired feed head button Head 1 or Head 2 K1542 13 Dual Procedure Memory Panel This...

Страница 24: ...n Burn back defaults to the on board trimmer adjustment When used with the Dual Procedure or Memory options only the WFS Amps and Volts Trim settings are saved Selecting the Gouge mode immediately ene...

Страница 25: ...displayed value in the cor responding direction Holding the switch in either direc tion will cause the display to move quickly in the corre sponding direction until the switch is released or the upper...

Страница 26: ...edure A limits can be set With system power on select the weld mode for which you want to set limits If a Dual Procedure option is installed select the procedure A Turn the system power off Remove the...

Страница 27: ...ogic With Crater Fill ON 1 Closing the gun trigger initiates the welding sequence preflow run in etc 2 Opening the trigger after the welding arc is estab lished allows the weld to continue as long as...

Страница 28: ...ar Make sure that the Release Bar pops up and that the collar retainers fully engage the retaining groove on the spindle 4 Rotate the spindle and adapter so the retaining spring is at the 12 o clock p...

Страница 29: ...eel laying flat on the floor loosen the spinner nut and remove the reel cover See Figure B 2 2 Before cutting the tie wires place the coil of elec trode on the reel so it unwinds from the bottom as th...

Страница 30: ...ssure could cause birdnesting but too little pressure could cause wire feed slippage with load and or acceleration The optimum drive roll set ting can be determined as follows 1 Press end of gun again...

Страница 31: ...CHANGING At the end of a coil remove the last of the old elec trode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the follow ing procedure 1 Cut the...

Страница 32: ...n etc LED on any other nodes components Wire Feeder Control Box Etc The system component is not receiving input power or is faulty It should only blink for a few seconds until the system component nod...

Страница 33: ...r Local Authorized Lincoln Field Service Facility System normal and functional LED on any other nodes components Wire Feeder Control Box Etc System component node needs to be reprogrammed Contact your...

Страница 34: ...KP1505 1 16S 5 64 2 0 mm KP1505 5 64 3 32 2 4 mm KP1505 3 32 Cored Electrode 0 030 0 8 mm KP1505 035C 0 035 0 9 mm KP1505 035C 0 040 1 0 mm KP1505 045C 0 045 1 2 mm KP1505 045C 0 052 1 4 mm KP1505 052...

Страница 35: ...panel can be one of the following CV G M MX2 or MSP2 The features of each are described in the Operation section of this manual There are extra mounting holes in the upper and mid dle positions which...

Страница 36: ...ol setting increases the arc force making the arc more harsh but less likely to stick Decreasing the Arc Control setting decreases the arc force making the arc softer and smoother Constant Voltage CV...

Страница 37: ...n the downward direction Holding the switch in either direction will result in the indicator advancing at a high rate of speed in that direction until the switch is released When the indicator reaches...

Страница 38: ...e the Arc Control adjusts the arc force Increasing the Arc Control set ting increases the arc force making the arc more harsh but less likely to stick Decreasing the Arc Control setting decreases the...

Страница 39: ...l This panel allows for the selection of the feed head to be used in a two feed head system All selections are done with push buttons and indicator lights To select the feed head to be used simply pre...

Страница 40: ...is as follows 1 Turn off power 2 Remove the two screws from the front of the stan dard or option panel at the location you choose to install your new option middle of the Control Box cabinet Save the...

Страница 41: ...n panels by reversing the removal process While re installing the option panels ensure clearance between Optional Output Connector components Control Box wiring harness and option panel harness if any...

Страница 42: ...nput Connector by inserting it s leads into the white nylon clip located near the Optional Input Connector on the back wall of the Control Box cabinet Insert the choke leads only 10 Install an Optiona...

Страница 43: ...K1500 1 connector in the Power Feed wire feeder NON LINCOLN GUNS Most competitive guns can be connected to the Power Feed by using one of the K1500 series adapter kits GUN RECEIVER BUSHINGS AND ADAPTE...

Страница 44: ...ug of the Dual Procedure switch is to be connected to the two trigger leads of the welding gun per instructions shipped with the kit K683 1 DUAL PROCEDURE SWITCH The K683 3 Dual Procedure Switch is th...

Страница 45: ...ff power 2 Unlatch and swing open the small door Remove the two screws from the horizontal hinge rod Save the screws 3 While holding the door so it doesn t fall Slide the rod out sideways releasing th...

Страница 46: ...rection 2 Loosen the retaining screw which is also accessed from bottom of feeder using a 3 16 Allen wrench Continue to loosen the screw until the feed plate can be easily pulled off of the wire feede...

Страница 47: ...rm the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric...

Страница 48: ...d in gun and cable Check for mechanical restrictions in feeding path c Check for current position of drive rolls Relative to split wire guide groove d Drive rolls may not be seated properly e Gun cabl...

Страница 49: ...poor work connection Replace if neces sary c Loose electrode or work cable connections d Wrong polarity Make sure elec trode polarity is correct for process being used e Gas nozzle extended beyond gun...

Страница 50: ...age is present and solenoid is on Feed head and Control Box status LEDs are both solid green a Tip overheating due to prolonged or excessive high current and or duty cycle welding Note A light applica...

Страница 51: ...s lights are solid green Preset WFS is adjustable on Control Box 9 Wire feed motor turns and sole noid operates but no arc voltage is present Status light is solid green on Control Box a Faulty gun tr...

Страница 52: ...are set to the same value b Possible problem with current sensor electronics in power source Check power source man ual to trouble shoot current sensor electronics a 67 and or 21 voltage sense leads...

Страница 53: ...ssistance before you proceed CAUTION PROBLEMS SYMPTOMS POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 14 Displays and or indicator lights do not change when their corre sponding switches and or knobs are...

Страница 54: ...switch Status lights are solid green on CB and head boards a Power source is OFF b Feeder supply or fuse circuit at power source is blown or tripped or defective harness or cabling c Display or CB boa...

Страница 55: ...rocedure switch or CB mother board Disconnect harness plug from J5 of CB mother board Check that there is continuity between plug pins 1 and 7 local DPS is in posi tion A but not when in gun or B Now...

Страница 56: ...has its feed head dip switches set to zero in a group with more than one object Did not receive a recognition com mand from the power source Make sure the group dip switch set ting is unique for each...

Страница 57: ...m the PS No heart beat response from an object EEPROM error Check for potential electrical HF noise generators in the area Try removing the noise source and pro gramming again If the Err 020 still occ...

Страница 58: ...shows any of the following Err 211 Err 212 three dashes Microprocessor RAM error in Control Box Microprocessor RAM Error in object board other than Control Box Such as feed head Appears on right disp...

Страница 59: ...gram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the...

Страница 60: ...F 2 DIAGRAMS F 2 POWER FEED 10 DUAL 6 88 218 4 25 75 75 81 90 12 07 12 96 18963 3 06 8 50 M 4 08 3 86 4 KEYHOLE SLOTS 10 17 97 CONTROL BOX DIMENSION PRINT...

Страница 61: ...F 3 DIAGRAMS F 3 POWER FEED 10 DUAL 19 89 A A 19 9 A A 15 41 A A 30 61 A A L11044 7 21 2000C WIRE FEEDER BENCH MODEL DIMENSION PRINT...

Страница 62: ...GRAMS F 4 POWER FEED 10 DUAL 8 56 A A 14 1 0 A A 15 5 5 A A 6 00 A A DOOR OPEN TYP 5 25 A A 19 4 3 A A 11 1 2 A A 2 54 TYP A A 4 43 A A 2 25 A A 2 93 A A 4 25 TYP A A WIRE DRIVE DIMENSION PRINT 7 2000...

Страница 63: ...NOTES POWER FEED 10 DUAL...

Страница 64: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Страница 65: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Страница 66: ...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 World s Leader in Welding and Cutting Pr...

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