Lincoln Electric IM584-D - Manuals

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....

Page 3 - ii

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 andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...

Page 4 - iii

iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼsrecommendations. 8.c. Ground the ...

Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ

iv SAFETY iv 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 LʼArc 1. Protegez-vous contre la seco...

Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...

Page 7 - TABLE OF CONTENTS; Page; vi

vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications .......................................................................................................A-1Safety Precaution...

Page 8 - vii

Page Troubleshooting ..............................................................................................Section E Safety Precautions ...............................................................................................................E-1Troubleshooting Guide .......................

Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS – Power Feed 10 Wire Drive & Control Box

POWER FEED 10 A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS – Power Feed 10 Wire Drive & Control Box WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO * Also part of K1538-[ ] Boom package and K1541-[ ] Bench Feeder. Δ Dimensions do not include wire reel.# F...

Page 10 - SAFETY PRECAUTIONS; BOOM MOUNTING OF WIRE DRIVE UNIT

A-2 INSTALLATION POWER FEED 10 A-2 SAFETY PRECAUTIONS MOUNTING THE WIRE DRIVE UNIT BOOM MOUNTING OF WIRE DRIVE UNIT Mount the wire drive unit by means of the 4 holes inthe bottom of the wire drive c a s e . ( S e e F i g u r e A . 1 )The gearbox assembly is electrically “hot” when thegun trigger is ...

Page 11 - Remove plug button taped to inside of Control Box; DETERMINING RECEPTACLE CONFIGURATION; CONTROL CABLE; CONTROL CABLE CONNECTIONS; extend their length.

A-3 INSTALLATION POWER FEED 10 A-3 5. Remove plug button taped to inside of Control Box and insert it into hole on front panel of the WireDrive. MOUNTING THE CONTROL BOX (BOOMOR SEPARATED BENCH MODELS) The back plate of the Control Box has four keyholeslots for mounting. See Figure A.2 for the size ...

Page 12 - Typical Bench Feeder Connection:; CONTROL CABLE SPECIFICATIONS

A-4 INSTALLATION POWER FEED 10 A-4 Typical Bench Feeder Connection: Control cable is connected from the Power Wave 455output receptacle to the input receptacle on the backof the Wire Drive. Typical Boom Feeder Connection: One control cable is connected from the Power Wave455 output receptacle to the...

Page 13 - WORK CABLE CONNECTIONS; - If you need to operate at wire feed speeds above; CHANGING THE WIRE DRIVE RATIO; Minimum Copper Work Cable Size, AWG

A-5 INSTALLATION POWER FEED 10 A-5 Connect the one end of the electrode cable, to thepower source output terminal of the desired polarity.Connect the other end of the electrode cable to theconnection bar at the front of the wire drive feed plateusing the provided bolt and lockwasher. The e l e c -tr...

Page 14 - RATIO CHANGE PROCEDURE:

A-6 INSTALLATION POWER FEED 10 A-6 RATIO CHANGE PROCEDURE: 1) Pull open the Pressure Door. 2) Remove the Phillips head screw retaining the pin- ion gear to be changed and remove the gear. Ifthe gear is not easily accessible or difficult toremove, remove the feed plate from the gearbox. To remove fee...

Page 15 - CC modes override this switch regardless of position.; DIP SWITCH SETUP

S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up) Switch Off On 1 Standard speed gearbox limits adjustable High speed gearbox limits adjustable 2 WFS Display = inches/minute WFS Display = meters/minute 3 Left Display is always preset WFS Left Display is preset WF...

Page 16 - MSB

A-8 INSTALLATION POWER FEED 10 A-8 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 switch bank that is furthest to the right. S2 DIP Switch Bank on C...

Page 18 - Switch position must match actual gear box ratio of wire drive.; Setting Wire Drive Acceleration Rate Using

A-10 INSTALLATION POWER FEED 10 A-10 SETTING DIP SWITCHES IN THE WIREDRIVE There is one DIP switch bank on the control board ofthe wire drive. Itʼs labeled S1 and is located and ori-ented as shown in Figure A.4. FIGURE A.4 S1 DIP Switch on Wire Drive Control Board (For software version S24029-All &a...

Page 19 - WIRE FEED DRIVE ROLL KITS; (including the Magnum 450 Water Cooled gun); ELECTRIC SHOCK can kill.

A-11 INSTALLATION POWER FEED 10 A-11 WIRE FEED DRIVE ROLL KITS NOTE: T h e m a x i m u m r a t e d s o l i d a n d c o r e d w i r e sizes and selected drive ratios are shown onthe SPECIFICATIONS in the front of this sec-tion. The electrode sizes that can be fed with each roll andguide tube are sten...

Page 20 - Lincoln Innershield and Sub Arc Guns

A-12 INSTALLATION POWER FEED 10 A-12 Magnum 200 / 300 / 400 Guns The easiest and least expensive way to use Magnum200/300/400 guns with the Power Feed 10 wire feederis to order them with the K466-10 connector kit, or tobuy a completely assembled Magnum gun having theK466-10 connector (such as the K4...

Page 21 - GMAW SHIELDING GAS; Gas Guard Regulator -; The Gas Guard Regulator is; WIRE SPINDLE PLACEMENT; CYLINDER may explode if damaged.; • Keep cylinder upright and chained to

A-13 INSTALLATION POWER FEED 10 A-13 The upper location must be used for 50-60 lb. Readi-Reels, Spools and Coils. For smaller coils (44lb, 30lb, 10lb, etc.), the spindlecan be placed in either the upper or lower location.The goal is to make the wire path from the coil to thewire drive an entry into ...

Page 22 - OPTIONAL FEATURES INSTALLATION; OPTIONAL PANELS FOR CONTROL BOX; The CD panel must be installed in either the; BOOM AND BENCH CONVERSIONS; Linc-Net receptacles, installs in control

A-14 INSTALLATION POWER FEED 10 A-14 OPTIONAL FEATURES INSTALLATION A number of Optional Features are available for usewith Power Feed 10. Some Installation information isprovided in this section, REFER TO THE INSTRUC-T I O N S T H A T C O M E W I T H E A C H K I T F O RDETAILED INFORMATION REGARDIN...

Page 23 - OPERATION; RECOMMENDED PROCESSES; DUTY CYCLE; CONTROL BOX PANELS - UPPER PANEL

B-1 OPERATION POWER FEED 10 B-1 SAFETY PRECAUTIONS PRODUCT DESCRIPTION The Power Feed 10 is a high performance, digitallycontrolled, modular wire feeder. Properly equipped, itc a n s u p p o r t t h e G M A W , G M A W - P , F C A W , a n dSMAW processes. The Power Feed wire feeders aredesigned to b...

Page 24 - CONTROL BOX PANELS - “SMALL” OPTIONAL PANELS; It is not required to load all 6 memories at once,

B-2 OPERATION B-2 The user adjusts WFS according to factors such asweld size, penetration requirements, heat input, etc.The power source then uses the WFS setting to adjustits output characteristics (output voltage, output cur-rent) according to pre-programmed settings containedin the power source. ...

Page 25 - CONTROL BOX PANELS -- ʻLARGEʼ OPTION PANELS

B-3 OPERATION B-3 Memory has an advanced feature called ʻmemoryreminderʼ. When the Save key is hit, the memoryreminder function flashes the LED of the most recentlyused memory, so the operator can save procedures inthe most recently used memory if desired. It is notnecessary to save to the most rece...

Page 26 - Preflow; - Time delay after the trigger is pulled, but; Run In; - Wire feed speed during arc starting. Wire; Arc Control; - Time delay after the trigger is released; Postflow

B-4 OPERATION B-4 POWER FEED 10 The value of the active Set Up parameter, as definedby the Set Up LED, is displayed on the MX2 panel SetUp display. The value can be modified with the Sets w i t c h . T h e S e t s w i t c h i s a n u p / d o w n c e n t e r - o f fmomentary toggle switch. Moving the...

Page 27 - Crater; The motor acceleration can be varied

B-5 OPERATION B-5 Crater - Used only when welding with the 4-Step trig- g e r m o d e . C a n b e s e t t o O f f o r O n . W h e n O n ,Adjustments can be made to WFS and Volts/Trim onthe Control/Display panel. These settings are thenused for ʻcrateringʼ when in the 4-Step trigger mode( s e e e x p...

Page 28 - WIRE DRIVE OPERATION; When using 2 Step Logic:

B-6 OPERATION B-6 O P E R AT I O N W I T H P R E V I O U SSOFTWARE VERSION The operation of the previous Control Box softwareversion (S24004-2) is different than described earlierin this section. The differences are as follows: • The Memory/Dual Procedure panel is not a valid option. • The MX (K1542...

Page 29 - LOWER; CAUTION

B-7 OPERATION B-7 WIRE DRIVE -- PC BOARD ADJUSTMENTS ELECTRODE POLARITY: The system needs to be aware of the electrode polari-ty. A DIP switch setting on the Wire Drive PC board isused for this purpose. See INSTALLATION Section“Setting DIP Switches in the Wire Drive”. GEAR BOX RATIO: The systems nee...

Page 31 - DRIVE ROLL PRESSURE SETTING

B-9 OPERATION B-9 FEEDING ELECTRODE AND BRAKEADJUSTMENT 1) Turn the Reel or spool until the free end of the electrode is accessible. 2) While tightly holding the electrode, cut off the bent end and straighten the first 6" (150 mm). Cut offthe first 1" (25 mm). (If the electrode is not proper...

Page 32 - MAKING A WELD

B-10 OPERATION B-10 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” in the...

Page 33 - COMPONENT STATUS LIGHTS; ON and steady

B-11 OPERATION B-11 COMPONENT STATUS LIGHTS Each network component has a single status light.The light is a bicolor, Green/Red, LED. The purposeof the status light is to allow the operator to quicklyidentify that the system is working properly or, if not, which component is causing the problem. By u...

Page 34 - LED State; System normal and functional.; Normal Blinking LED -; Each illumination should exist for 0.5 seconds.

B-12 OPERATION B-12 POWER FEED 10 STATUS LIGHT STATES (CONʼT) LED State Red LED blinkingat a fast rate Red LED ON andsteady G r e e n L E D O Nand steady Power Source LED Power source needs to be reprogrammed.Contact your Local Authorized Lincoln FieldService Facility. Power source has a non-recover...

Page 35 - ACCESSORIES

C-1 ACCESSORIES C-1 POWER FEED 10 TABLE C.1 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4-Roll DH Drive (4-Driven) Solid Steel Electrode 0.023” - 0.025” (0.6 mm) KP1505 - 030S 0.030” (0.8 mm) KP1505 - 030S 0.035” (0.9 mm) KP1505 - 035S 0.040” (1.0 mm) KP1505 - 040S 0.040” (1.0 mm) KP1505 - 045S 0.045...

Page 37 - Installation is as follows:

C-3 ACCESSORIES C-3 K1542-6 “M” PANEL The M Panel provides a fixed large bat toggle switchselection of three Power Source modes. The upperposition selects the generic CV/MIG mode from thep o w e r s o u r c e , t h e m i d d l e p o s i t i o n s e l e c t s t h eC V / F L U X C O R E D m o d e , a ...

Page 39 - 5° deactivates the out-

C-5 ACCESSORIES C-5 K1542-12 MSP2 PANEL AND K1542-10 MS/STT PANEL (LARGE PANEL) The MSP2 or MS/STT Panel provides a selection ofnumerous process specific and generic Power Sourcemodes. In addition, it provides for the adjustment ofthe following parameters: preflow, run in, arc control,burnback, post...

Page 42 - Control Box Cabinet Procedure

C-8 ACCESSORIES C-8 K 1 5 4 8 - 1 L I N C N E T R E C E P TA C L EKIT (INPUT AND OUTPUT) LINC NET RECEPTACLE (OUTPUT) Optional Output Connector Installation into the ControlBox Cabinet and/or into the Feeder Head Enclosure. Control Box Cabinet Procedure 1. Turn off power. 2. Remove the screws from t...

Page 43 - K162H - WIRE SPINDLE ADAPTER

C-9 ACCESSORIES C-9 LINC NET RECEPTACLE (INPUT) Power Feed Wire Feeder Optional Input ConnectorI n s t a l l a t i o n i n t o t h e C o n t r o l B o x C a b i n e t a n dConversion to Fixture Wire Feeder 1. Turn off power. 2. Remove the screws from the front of the lower and middle option panels o...

Page 44 - GUNS AND GUN ADAPTERS; LINCOLN FUME EXTRACTION GUNS

C-10 ACCESSORIES C-10 GUNS AND GUN ADAPTERS The Power Feed 10 wire feeder is equipped with afactory installed K1500-2 gun connection Kit. This kitis for guns having a Tweco™ #2-#4 connector. ThePower Feed 10 has been designed to make connect-ing a variety of guns easy and inexpensive with theK1500 s...

Page 45 - CONDUIT ADAPTERS; K683-3 DUAL PROCEDURE SWITCH; Configuration 1

C-11 ACCESSORIES C-11 CONDUIT ADAPTERS K1546-2 ADAPTER for use with Lincoln Magnum conduit and E-Beamconduit (wire sizes 1/16 - .120) For Magnum conduit: Install the K1546-2 gun adapter at the incoming end ofthe feed plate, secure with the set screw located atthe back of the feed plate. If a brass f...

Page 47 - Avoiding Wire Feeding Problems; Wire Drive Motor and Gearbox; MAINTENANCE; Safety Precautions; Drive Rolls and Guide Tubes

D-1 MAINTENANCE D-1 POWER FEED 10 Avoiding Wire Feeding Problems Wire feeding problems can be avoided by observingthe following gun handling and feeder set up proce-dures:a) Do not kink or pull cable around sharp corners. b) Keep the electrode cable as straight as possible when welding or loading el...

Page 48 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.

E-1 TROUBLESHOOTING E-1 POWER FEED 10 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. CAUTION This Troubleshooting ...

Page 49 - PROBLEMS; Contact

E-2 TROUBLESHOOTING E-2 POWER FEED 10 Observe all Safety Guidelines detailed throughout this manual 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 troubleshootin...

Page 52 - Observe all Safety Guidelines detailed throughout this manual; a. Defective motor tach or control

E-5 TROUBLESHOOTING E-5 POWER FEED 10 Observe all Safety Guidelines detailed throughout this manual 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 troubleshootin...

Page 54 - a. The encoders or switches may be

E-7 TROUBLESHOOTING E-7 POWER FEED 10 Observe all Safety Guidelines detailed throughout this manual 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 troubleshootin...

Page 57 - Display shows any of the following:; Err; Too many objects in group.

E-10 TROUBLESHOOTING E-10 POWER FEED 10 Observe all Safety Guidelines detailed throughout this manual Note: For any Err # listed below write down the error number for reference and try cycling power to see if theerror clears itself. If not, refer to the What to Do column for the given Err. If for an...

Page 58 - See what to Do on Err 006.

E-11 TROUBLESHOOTING E-11 POWER FEED 10 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. CAUTION Observe all Safety ...

Page 60 - DIAGRAMS

F-1 DIAGRAMS F-1 POWER FEED 10 50 0D LINC-NET D C 54 0 B A TOROID R.F. (OPTIONAL FOR E BOOM SET UP) 50 0 E (P7) RECEPTACLE TOROID N.B. N.D. 500 2 3 4 540 (J6) INPUT 542 541 R.F. (J8) P.C. BOARD ENCODER DUAL LOWER OPTION N.E. 1 2 1 43 43 2 4 3 3 4 2 1 540A 500A 542A 541A 12 6 500D 542D 541D 2 1 51 2C...

Page 61 - WI

F-2 DIAGRAMS F-2 POWER FEED 10 2 4 5 7 8 542 541 N.E. A E D AC C B A TO R O ID LINC-NE T 67 (J6) 500 540 E 67 4 1 541D 540C 542D 500D 1 2 1 6 L10587 R E C TIFIER 553 AC A 6 4 - (J2) N.A. 5 A 10 540C 4 3 4 3 N.D. 558 512 A 560 67A 7 N.A. A 4 (J1) 512 N.C. 1 12 10 2 3 4 R - RED B LE A D COLOR CODING 4...

Page 62 - DIMENSION PRINT

F-3 DIAGRAMS F-3 POWER FEED 10 2.34 18.58 13.50 30.48 14.60 DIMENSION PRINT P OWER FEED 10 7-2000 L10599

Page 63 - NOTES