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Power Feed 10 Wire Drive & Control Box

Boom Mount or Bench Model

OPERATOR’S MANUAL

IM584-D

August, 2007

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.

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.

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

• 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

• World's Leader in Welding and Cutting Products •

Содержание POWER FEED IM584-D

Страница 1: ...d most importantly think before you act and be careful 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...

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: ...i 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 paisse pan t...

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: ...nnection Guidelines A 12 GMAW Shielding Gas A 13 Gas Guard Regulator A 13 Wire Spindle Placement A 13 Water Connections For Water Cooled Guns A 13 Wire Feed Shut Down Circuit Optional A 13 Optional Fe...

Страница 8: ...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 Li...

Страница 9: ...5 1200 IPM 025 1 16 in 035 5 64 in 2 3 4 Boom Package 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 5 6 K1541 1 Power Feed 10 50 800 IPM 025 3 32 in 035 125 in 75 1200 IPM 02...

Страница 10: ...y 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 re...

Страница 11: ...nstalling 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...

Страница 12: ...ontrol cables are copper 5 conductor cable in a SO type rubber jacket There is one 20 gauge twist ed pair for network communications This pair has an impedance of approximately 120 ohms and a propa ga...

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

Страница 14: ...rger gear for high speed feed er If feed plate does not rotate to allow holes to line up further loosen the screw on right face of feed plate 5 Remove the small gear from the output shaft Lightly cove...

Страница 15: ...Memory change with trigger disabled Memory change with trigger enabled 6 Acceleration MSB Sets acceleration rate for wire drive see below 7 Acceleration Sets acceleration rate for wire drive see belo...

Страница 16: ...and S2 switches is OFF S1 DIP Switch Bank on Control Box Motherboard For software version S24004 2 only Switch Off On 1 US 4 Step Trigger Logic Euro 4 Step Trigger Logic 2 WFS Display inches minute WF...

Страница 17: ...ow MSB Most Significant Bit or Byte This is the bit in a binary number or DIP switch bank that is furthest to the left LSB Least Significant Bit or Byte This is the bit in a binary number or DIP switc...

Страница 18: ...head number to wire drive 5 Network Feed Head ID LSB Assigns feed head number to wire drive 6 Spare 7 Electrode Sense Polarity Positive Electrode Sense Polarity Negative Switch position must match po...

Страница 19: ...nnection 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 ki...

Страница 20: ...plate to allow a bolted brass to brass electrical connection to be made direct ly to either standard or Fast mate gun adapter bush ings Use a 1 4 inch allen key on the factory installed socket head c...

Страница 21: ...truc 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 flow control valve and a h...

Страница 22: ...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 t...

Страница 23: ...Code or any applicable local codes Only qualified personnel should perform this installation WARNING RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Power Feed 10 can be set up in a num...

Страница 24: ...rmined by the dual procedure weld ing gun switch Note When in the Gun Switch mode this option does not have provisions for indicat ing which remotely selected procedure A or B is active To set Procedu...

Страница 25: ...ion 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 e...

Страница 26: ...played 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 or...

Страница 27: ...rocedure 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...

Страница 28: ...c When using 4 Step Logic With Crater Fill OFF 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 t...

Страница 29: ...llar 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...

Страница 30: ...h reel 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...

Страница 31: ...essure 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 agai...

Страница 32: ...REEL 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...

Страница 33: ...tc 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 node h...

Страница 34: ...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 L...

Страница 35: ...505 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 052C 1...

Страница 36: ...turned off To remove a panel remove the two screws holding it in place remove the push on chassis ground wire and remove the harness connection to the Control Box main PC board To install any panel re...

Страница 37: ...trol 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 C...

Страница 38: ...advances it in 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 indi...

Страница 39: ...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 arc f...

Страница 40: ...connections and the print ed circuit board on the back 5 Align the screw holes replace the two screws and tighten K1542 9 DUAL PROCEDURE MEMORY PANEL SMALL PANEL Note This panel will function with S24...

Страница 41: ...ve the chas sis wire if equipped from the back of the stan dard or option panel Discard the old panel or save for future use 3 Tilt the new option panel away from the front opening of the Control Box...

Страница 42: ...ion 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 a...

Страница 43: ...e Optional Input 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 Instal...

Страница 44: ...K206 K289 and K309 require only the installa tion of a 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 K15...

Страница 45: ...plug 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...

Страница 46: ...it to the Power Feed 10 This option is compatible with the K1557 1 Swivel Mount K1574 1 SECURITY DOOR LARGE K1574 1 Security Door Installation into the Control Box Cabinet 1 Turn off power 2 Unlatch...

Страница 47: ...tion 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 feedplate can be easily pulled off of the wire feeder MA...

Страница 48: ...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 Fa...

Страница 49: ...n 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 cable d...

Страница 50: ...r 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 ti...

Страница 51: ...e 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 applicati...

Страница 52: ...ights 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 trigg...

Страница 53: ...e 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 may...

Страница 54: ...stance 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 ac...

Страница 55: ...hts are solid green on Circuit Boards 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 Circuit Boa...

Страница 56: ...cedure switch or Circuit Boards mother board Disconnect harness plug from J5 of Circuit Board mother board Check that there is conti nuity between plug pins 1 and 7 local DPS is in position A but not...

Страница 57: ...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 Cir...

Страница 58: ...wer Source 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 o...

Страница 59: ...ny 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 display of C...

Страница 60: ...E N C PIN NEAREST THE FLAT EDGE OF LED LENS CATHODE ALIGNS WITH BLACK LEAD OF LED SOCKET L10586 500 8 7 W B NOTES N A CAVITY NUMBERING SEQUENCE AS VIEWED FROM COMPONENT SIDE OF PC BOARD N F CAVITY NUM...

Страница 61: ...40B 542D 541D 9 7 D 4 3 1 6 N A A D C 556 557 555 6 540A 500A 542A 67 W INPUT ELECTRODE CABLE A 1 559 J5 560 B E 4 3 2 J7 TOROID FILTER 4 PC BD J1 1 2 3 4 N D TOGGLE SWITCHES SHOWN FROM CONNECTION SID...

Страница 62: ...F 3 DIAGRAMS F 3 POWER FEED 10 2 34 18 58 13 50 30 48 14 60 DIMENSION PRINT POWER FEED 10 7 2000 L10599...

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

Страница 64: ...NOTES POWER FEED 10...

Страница 65: ...NOTES POWER FEED 10...

Страница 66: ...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 67: ...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 68: ...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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